Professional Documents
Culture Documents
and Components
Mitsubishi Hitachi Power Systems Europe
e
a
A Before being injected into the furnace, the raw coal is crushed down to a fine pulverized form
in the coal mills.
2 Flue gases up to 1,450 °C arise from pulverized fuel combustion in the steam generator furnace.
The liberated heat is used to generate high-pressure and high-temperature steam.
3 The steam is directed to a turbine; it flows onto the blade wheels and turns the turbine shaft.
An attached generator then generates the electrical power.
Contents 4 With the help of catalysts, the nitrogen oxides in the flue gas react in the DeNOx system
to produce nitrogen and water vapor.
Mitsubishi Hitachi Power
Systems Europe 2 5 Ash particles adhere to electrically-charged surfaces in the electrostatic precipitator;
Selection Criteria 5 they are rapped and removed from the flue gas.
Furnace 6 6 In the flue gas desulphurization system (FGD) lime slurry or suspended pulverized limestone
Mill Feeders 8 bind the sulphur dioxide coming from the flue gas. The final product arising is gypsum.
Pulverizers 10
Pulverized Fuel Burners 14
Burn-Out Grate 20
Ash Removal Systems 21
Replacement Parts Service 23
Stronger together
The merger of the “thermal power plant” fields of Mitsubishi Heavy Industries, Ltd., (MHI) Stakeholders in Mitsubishi Hitachi
Power Systems Europe GmbH
and H
itachi, Ltd., has brought about Mitsubishi Hitachi Power Systems, Ltd., (MHPS) – one of
the world’s largest companies in thermal power generation systems. MHI Hitachi, Ltd.
An important mainstay of this corporate group is Mitsubishi Hitachi Power Systems Europe 65% 35%
GmbH (MHPSE), the successor to Hitachi Power Europe GmbH. The energy plant con MHPS
structor (based in Duisburg) looks back over a +100-year track record in planning and
100%
constructing fossil-fired power plants. MHPSE constructs turnkey plants, supplies key
components (e. g. utility steam generators, environmental engineering equipment, turbines, MHPSE
SUBSIDIARIES
AND RELATED
COMPANIES
As one of the global cutting-edge companies in power plant design and construction,
Mitsubishi Hitachi Power Systems Europe provides highly advanced firing systems which can
be used in their entirety or as single components for practically all fossil fuel qualities.
MHPSE develops solutions, which are just as flexible as our customers’ requirements, for
energy suppliers and industry alike. This can be seen most clearly from the large number of
different types of references (see table) available. A high degree of operational efficiency and
conservation of resources / environment is looked upon as an obligation and challenge by
MHPSE in designing and manufacturing new utility steam generators. This also applies to the
modernization and enhancement of existing power plants and their components, such as
pulverizers and burners.
It goes without saying that MHPSE as a certificated DIN ISO 9001 company always orientates
itself to the best possible quality.
What Counts is the Choice
The planning and design of firing systems is primarily dependent on the fuel used and
must be individually tailored – something requiring above-average achievements on the part
of our designers.
Whilst there is no secret about up-to-date firing systems, one still needs considerable
know-how and a long track record in plant concepts and specific sequences. Playing a prime
role here are the fuel properties themselves, such as calorific value, moisture and ash content,
volatiles and coal grindability.
Advanced firing systems with a staged combustion sequence lower emissions and require
substantial design and material selection outlay on the basis of the standards and legislation
in force. This applies equally to the selection and construction of the firing components.
The principal features are: Fossil-fired power plants are currently enjoying a boom across the world. And hard coals,
■■ Uniform liberation of heat
in particular, can be widely used for energy transformation purposes.
■■ Low nitrogen oxide emissions
coupled with practically a total
fuel transformation The decision to design a firing system with dry bottom ash removal or as a slag-tap furnace
■■ Oxygen-rich flue gas atmosphere largely depends on the fuel properties themselves. Volatile matter, ash content and chemical
right next to the boiler tube walls
ash composition have always been of decisive significance.
The decision-making process was simplified with the launching of innovative DS® burners
followed by tremendous combustion stability. Modern steam generators are usually designed
today solely as dry ash discharging boiler plants at low cost and high efficiencies. This applies
to practically the entire range of fuels irrespective of their effects from high volatile bituminous
coal to anthracite.
For many years now, the linear arrangement as front, double-front or opposed firing equip
ment complete with vertically offset burner levels has proved to be the most suitable system
for pulverized hard coal firing systems.
The clear arrangement of mill and burner level ensures that the highly complex systems are
clearly designed and arranged. This, in turn, creates a high degree of accessibility and ease
of maintenance.
Combustion systems for lignite operated steam generators can be designed as direct
systems for the use of raw lignite or as combined systems using raw and pre-dried lignite
in the same furnace.
Even with the usage of very high ash lignites, the new MHPSE lignite swirl burners (RS® burn
ers) do not need any vapor separation.
The excellent igniting stability of the RS® burners allows the burners to be arranged in a
different way at the combustion chamber – for instance in the form of an all-wall firing system.
Such a system combines the benefits of linear firing equipment with those of a tangential
firing system. The firing steps alone enable the 200 mg/m3 NOx standard to be undercut in
RS® burners. As a result, there is no need for complex, multiple air-staging concepts for
adherence to the NOx standards.
The stable ignition of RS® burners produces a marked improvement in the percentage load
operations of lignite firing systems. Even with problematical fuels, the excess stoichiometric
operation of these burners has a positive effect on fouling and slagging and it optimally
protects the evaporator tube walls from corrosive flue gas products.
The future will see boiler plants mainly being planned for the use of dry pulverized lignite with
interim storage.
Belt conveyor
Designed as coal bunker dischargers, the mill feeders supply the pulverizers with raw coal –
evenly dosed and in keeping with boiler load requirements.
Even under very demanding requirements, the Mitsubishi Hitachi Power Systems Europe
designed mill feeders operate both reliably and safely.
Experienced MHPSE staff establish the optimum feeder in keeping with the requested fuel
quantity, design directives (including DIN EN 12952-9, NFPA 85 F) and customer require
ments (for instance, volumetric and gravimetric metering).
Other selection factors are the various bulk material properties, such as coal flow and erosion
behavior. The belt speed is determined by the quantity conveyed. Purge air is supplied to the
housing to stop condensate forming and, in turn, to stop corrosion.
In hard coal boiler units, belt conveyors are used to discharge the raw coal from the bunker.
In lignite plants, drag-chain conveyors together with belt conveyors are used to discharge the
raw coal from the bunker.
Belt conveyor
The belt conveyor with corrugated edge belt ensures high outputs, uniform bunker discharge
and continuous mill charging – even under low conveying rates. This design permits volumet
ric / gravimetric metering and quantities conveyed of up to 120 t/h. Conveyed material falling
to the bottom of the feeder is transferred to the coal downcomer by the simultaneously
running scraper chain.
Raw coal
g
a
d
A Bed depth limiter
B Belt drive station
c C Belt tensioning station
b h
D Corrugated edge belt
E Scraper chain
F Lower belt supporting roller
G Bunker shut off gate
e f
Conveyor-type weigher (optional)
Drag-chain conveyor
Dragchain conveyors are meant for limited conveyed quantities of up to approx. 40 t/h –
this can, in special cases, be raised to 70 t/h. The fuel is discharged opposite to the direction
of conveying. The dragchain conveyor principle allows both a compact design with minimum
spacing between bunker discharge and conveyor dumping as well as a possible large
spacing between material charging and dumping.
Raw coal
Excellent Results
In the mills, the raw coal is simultaneously pulverized, dried and evenly distributed to the coal
burners. Hot air or flue gases transfer the pulverized fuel to the burner and reduce the mois-
ture in the coal.
MPS® Mill
Various-sized mills for throughputs ranging from 10 t/h to 200 t/h can be supplied. Constant
refinements and improvements have led to excellent crushing results with high fineness
grades from raw coal found throughout the world. The positive operating
a
properties and low energy requirements have contributed in no small
b
measure to the success of these mills.
c
e
RKD Mill
a
g
b d e
A Rotary classifier
B Oversize return
f
C Neck bearing
D Drive gear rim
E Grinding ball filling
F Feed spiral conveyor
c G Classifier riser
Pulverizing lignite is particularly challenging in view of its high moisture content and the
considerable throughputs involved. Here again Mitsubishi Hitachi Power Systems Europe
has the right products in this segment.
DGS® Mill
DGS® technology involves the raw coal and flue gases being initially put through the pre-
crushing beater section of the beater wheel. This ensures excellent air and coal dust distribu
tion into the beater wheel. Crushing in the DGS® mill is u
sually so
intensive that adequate grinding fineness can be obtained in one
a working operation – without the need of an additional classifier.
c This both raises the pressure balance and cuts back on energy
requirements. The DGS® mill has stood the test of time par
f g
ticularly with difficult-to-work lignites – something that explains
b
its considerable lifetime and unrivalled properties.
g
NV Mill
Together with the flue gases, the raw lignite is brought for crushing purposes into the beater
wheel. It acts as a fan impeller fitted with beater plates. Baffle-type classifiers ensure that the
required fuel fineness for combustion is fulfilled.
e
f g
Optimum Combustion
How do you lower NOx emissions and at the same time control as many different fuels as
possible? Questions like these are today determining the concept of pulverized fuel firing
systems and burners.
DS® Burners
300 1,800
1,667 1,697
260 1,607
1,487 1,600
250
1,303 1,400
1,165
200 1,095 1,119 1,135 1,200
1,031 184
959
144 859 879 1,000
150 787 138
120 120 643 120 800
100 88 600
383 80
72 72
64
46 263 60 400
50 175
8 9 9 129 30 30
20 24
16 200
8 1 0
0 0 0
0 0
1991 1993 1995 1997 1999 2001 2003 2005 2007 2009 2011 2013 2015
n Total number n Year of commissioning
DS® burners were introduced early in the 1990s and continuously developed over the years.
The burner’s principle is focused on fuel treatment to prepare the particles for the pyrolysis
and ignition process that follows. The characteristic features of this burner type are expressed
by the definition of initiation and course of ignition.
This type of burner with a concentric design and swirled flow streams in all sections, has its
field of application mostly in direct firing systems using all kinds of pulverized fuels.
The DS® burner concept utilizes operating experience from more than 1,100 applications.
Igniter
DS® burners with an operating range of 1: 3,5 are available for direct operated combustion
systems in a range of thermal capacities from 20 to 100 MW.
Sub-bituminous coal x x x x
Bituminous coal x x x x x
Anthracite x x x
Biomass (standalone) x x
Basically developed for bituminous coal, these burners are applicable now for all carbon
containing solid fuels like anthracite, sub-bituminous coal, lignite and biomass of different
structures. The DS® burner is suitable for applications with individual air control as well as for
the use in common windboxes.
DST Burner
The DST burner has been developed on the basis of the DS® burner concept for use in
indirect firing systems.
This burner type is the right one for predried pulverized fuels like anthracite, bituminous and
subbituminous coal, lignite, peat, biomass of various types as well as further carboncon
taining pulverized fuels separately or in any combination. Dust loading can range from 0.5 up
to 15 kg fuel / kg medium.
DST burners can be used for atmospheric operation or in pressurized systems with air and / or
oxyfuel atmosphere.
Air, inert gas and flue gas with or without oxygen enrichment can be used as the transport
medium for the fuel.
DST burners can be operated with a turndown rate up to 1:17. As a result a boiler can be
operated from lowest startup load up to full load conditions with an unlimited load response
rate. Due to an extremely high PF / PA ratio the NOx emission rate is rapidly reduced.
DST burners are available for thermal capacities from 20 to 60 MW for all kinds of predried
pulverized fuels used in indirect firing systems.
Subbituminous coal x x x
Bituminous coal x x x
Anthracite x x x
Biomass (standalone) x x x
DS® burner direct (left)
DST burner indirect (right)
4
Burner control range (as tested)
Coal / PA Ratio [kg/kg]
3
Indirect firing system, DST burner
1
Direct firing system, DS® burner
minimum load range
0
0 5 10 15 20 25 30 35 40 45
Burner capacity [MW]
Energy storage and plant flexibility are the main challenges of power generation in the future.
With the DST burner control range of 1:17 coal firing systems will be best prepared to meet
the resulting operating demands.
DST Burner
M
M
100 %
M
75 %
M M
M M
50 %
M M
M 20 M 40 M 30 M 10
M M M
M M M M
25 %
Flexibility is what is demanded of power generation now and in the future. With development
of the DST burner, flexible concepts using indirect firing systems are now becoming the focus
of interest.
The combined firing system using the advantages of the direct and indirect systems is the
consequential answer to the fascinating questions surrounding coal fired power plants in
facing the challenges of the future.
RS® Burner
RS® Burners
70 160
Orders since 1994
142
60 140
124 124
50 48
120
100 100 100 100 100 100 100
100
40
76 76
80
30 64
24 24 60
20 18
40
16 16 12
10 4 4 10 10
6 20
4 0 6 0
0 0 0 0 0 0 0 0 0
0 0
1994 1996 1998 2000 2002 2004 2006 2008 2010 2012
n Total number n Year of commissioning
The extensive findings acquired from developing DS® burner technology (flame stability, igni
tion as well as air staging in the burner proximate zone) are also available for lignite firing
technology purposes.
What has been developed is the lignite RS® burner. In contrast to the conventional jet burner,
the RS® burner permits control of the fuel / air mixture and flame propagation in the burner
proximate zone.
Radiant
Secondary Air Shielding Pipe
Pulverized Fuel
Cooling Air
Coal Dust
Secondary Air Deflecting Cone
High Efficiencies
In lignite coal or peat-fired plants with a high proportion of xylitol or fibers in the fuel,
the proportion of unburnt residue in the boiler hopper ash can be extremely high and this
impairs firing efficiency.
f
d
The optimum designed burnout grate ensures that the ash burnout in the boiler hopper is
improved to over 80 % – thus substantially raising the overall efficiency of the boiler plant.
In addition, afterburning results in additional heat input into the boiler hopper, which would
otherwise be relatively cold. This leads to an even distribution of temperature in the furnace.
Ash Removal
Ash removal systems have been part of MHPSE’s range of production and supplies for many
years now. This applies to bottom ash removal as well as to the transfer of ash accumulating
in the course of air heater and electrostatic precipitator ash removal.
c a b i f
1 Bottom ash
f k g j k d k g k
➞
➞
Conveying
direction
MHPSE provides a broad range of ash handling systems. These systems apply to ash handling
for furnace bottom ash removal and also to the ash removal from all downstream ash
accumulation points.
Our systems offer a lot of benefits: they are stable in the extreme, wear parts are long lasting
and both the energy requirements and operating / upkeep costs are low. MHPSE provides
the entire range for utility steam generators with pulverized hard coal and lignite firing: from
design, manufacturing and erection up to commissioning the complete ash disposal systems
including loading systems for transport by truck, rail and ship.
■■ Ash silos and dewatering bunker ■■ Dry mechanical ash removal systems
■■ Single-strand chain conveyors ■■ Hydraulic ash removal systems
■■ Apron conveyor ■■ Pneumatic ash removal systems
■■ Screw conveyors ■■ Mill reject systems
■■ Single and double roller crushers ■■ Re-cooling systems for submerged
■■ Hammer crushers conveyor overflow water
■■ Rotary feeders
■■ Single and double pendulum flap
■■ Shut off gates
■■ Ejectors
■■ Bucket-type conveyors
■■ Sluice ways
Replacement Parts Service
As a designer and manufacturer of original components, MHPSE is the ideal partner to contact
when modernization or replacement parts are needed.
Our extensive expertise derived from designing and delivering utility steam generators
with the associated components over many years enables our MHPSE experts to provide
professional solutions matched to customer requirements in the matter of plant design and
operations. Optimized plants ensure that performance and availability are raised and that
efficient operations are attained as far as possible. As a competent and flexible partner,
MHPSE’ expertise is available in the fields of process engineering, plant optimization, measur
ing technology, plantinternal inspection, component installation and commissioning. At the
same time, MHPSE supports customers in the design and configuration of their future
plants – from the technical point of view (planning, design, optimizing) and in the matter of
operating economy analyses.
Rapid Servic
e from
a Competent
Partner
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