Combustion Optimisation of Blended Coal 27-02-13 PDF

Bharat Heavy Electricals Limited, Tiruchirapalli
“Combustion optimization of blended coal“ 27 02 2013

“Combustion
International seminar on “Combustion
optimization of blended
optimization
coal“of blended coal“ 27 02 201328 01 2013
Blending & Its effect on boiler design
Coals can be Blended and successfully fired in any new

unit that has been designed to handle such fuels
Proper design depends on the complete knowledge of
the coals that are to be blended
Performance of blended coals cannot be entirely
predicted by arithmetic proportioning of the
constituents
International
Workshop“Combustion
on Coal seminar
optimization
Blending,on “Combustion
Imported of blended
coal firingoptimization
coal“
& combustionoftuning
blended coal“ 27 02
2827
01
2013 2013
– 28 July12
Coal Properties Affecting Boiler Performance of Blended Coal
a. Moisture
b. Volatile matter
c. Ash
d. Fixed carbon
e. Calorific value
f. Grindability
g. Ash composition
h. Petrography
International
Workshop on Coal“Combustion
seminar
optimization
Imported coal firingof
optimization
&blended coal“
combustionoftuning
blended coal“ 27 02 2013 282701 2013
– 28 July12
Effect of Moisture on Boiler performance
Moisture has great impact on the capacity of the Mill and hence the
mill selection.
High moisture coal needs more heat for drying the coal affecting
Economizer and Air heater Sizing
Low Moisture coals needs lesser heat to dry the coal, and hence a
lower hot air temperature at mill inlet.
High moisture decreases boiler efficiency through latent and
sensible heat loss when the moisture of the blended coal is high,
pulveriser capacity will reduce (More number of mills may be
required for normal operation)
When the moisture of the blended coal is low, pulveriser capacity
will improve (Less number of mills may be required for normal
operation)
International
seminar
optimization
optimization
&blended coal“
combustionoftuning
blended coal“ 27 02 2013 282701 2013
– 28 July12
Effect of Volatile matter on Boiler performance

Volatile matter of blend is dependent on volatile matter of each coal particle
If the blend contains two coals with significantly different volatile contents, two
flames can develop, based on the devolatilisation of each of the blended coal
Blending of a low volatile coal with a small proportion of high volatile coal aids
in flame stability and uniform heat transfer in boiler.
When the Volatile matter of the blended coal is low, flame stability decreases
(Continuous support of oil may be required for normal operation)
When the Volatile matter of the blended coal is high, pulveriser outlet
temperature is to be decreased correspondingly which will directly reduce the
boiler efficiency
International
Workshop “Combustion
on Coal seminar
optimization
Imported of
optimization
coal firing &blended coal“
oftuning
combustion blended coal“ 27 02 2013 282701 2013
– 28 July12
Effect of Ash on Boiler Design
The percentage of ash present in the fuel and the characteristic of ash dictates
the sizing of the furnace.
Fuel with ash characteristics leading to slagging and fouling requires a

conservatively sized furnace since ash quantity Influences the furnace heat
transfer by shielding the radiation. Flame temperature lowered by increased
ash quantum
The ESP selection is mainly based on the quantity of ash generated.
When the Ash % of the blended coal is low..
 Furnace size could be reduced
 SH/RH & Economiser heat transfer area could be reduced by adopting

higher flue gas velocity)
 ESP size could be reduced
International
Workshop on“Combustion
Coal seminar
Blending,optimization
on “Combustion
Imported coaloffiring
blended
optimization
coal“ oftuning
& combustion blended coal“ 27 02 2013
282701 2013
– 28 July12
Effect of Fixed carbon on Boiler performance
Fuel ratio = Fixed carbon/Volatile matter
When the Fuel ratio % of the blended coal is High…

Difficult to burn and the un-burnt’s in combustion will increase which
leads to poor boiler efficiency.
When the Fuel ratio % of the blended coal is low…

The coal is easy to combust and shall result in reduced un-burnt
carbon loss and better boiler efficiency.
International
seminar
optimization
optimization
&blended coal“
combustionoftuning
27 01 2013 282701 2013
– 28 July12
Effect of Calorific value on Boiler performance

Decides the quantity of the coal to be fired.
Decides the fuel preparation and firing system design including
number of pulverisers, Wind box burner elevations etc.,
Decides the furnace size, configuration, auxiliary selection and
boiler layout.
When the Calorific value differs substantially, the % blending should

be restricted.
Careful Field trials are mandatory before increasing % of blending
International
seminar
optimization
optimization
&blended coal“
combustionoftuning
27 01 2013 282701 2013
– 28 July12
Effect of grindability index on Boiler performance

Coal grindability expressed as HGI affects the pulveriser selection and operation
directly
Grindability index of blended coal is Not proportional to weighted Grindability

index % of individual coal Grindability index % used for blending
Indiscriminate blending of coals with different Grindability index will lead to

preferential grinding. The required fineness may not be possible to achieve,
resulting in high unburnt combustibles
Generally Mill capacities for coal blends are difficult to evaluate using existing
grindability correlations
But Pulveriser performance more closely resemble that of harder coal
Suggested to restrict the difference in Grindability index between the constituent

coals of the blend to be within 20 HGI
International
seminar
optimization
optimization
&blended coal“
combustionoftuning
27 01 2013 282701 2013
– 28 July12
Ash Analysis
Provides indicators to
Slagging / fouling / deposition potential
Erosion potential
Corrosion potential
Contd …
International
seminar
optimization
optimization
&blended coal“
combustionoftuning
27 01 2013 282701 2013
– 28 July12
Ash Analysis
Slagging & fouling propensity of coals
 The viscosity of laboratory ash
 Ash fusion temperature
 Various laboratory ash composition ratios
Iron : Calcium
Silica : Alumina
Base : Acid
 Sodium-in-ash content
 Total alkali metal content in laboratory ash
Segregation of ash during pulverising & its properties
International
seminar
optimization
optimization
&blended coal“
combustionoftuning
27 01 2013 282701 2013
– 28 July12
Ash deposition in a boiler is an extremely complex

process…..
The rate of deposit buildup depends on eutectic formation like
Sodium sulphate, Calcium sulphate, Sodium silicate etc..
Blending of coals can cause the ash such that eutectic of two
minerals can have a lower melting temperature than that
produced by either acting alone
During blending the combination of Iron, Sulphur, Sodium,

Potassium and Calcium contents are to be evaluated.
International
seminar
optimization
optimization
&blended coal“
combustionoftuning
27 01 2013 282701 2013
– 28 July12
Emissions
Coal quality influences particulate, SO2 and NOx emissions
A coal blend affects ESP performance primarily through the

influence of the chemical & physical properties of fly ash
 Fly ash resistivity

 Fly ash chemistry
 Fly ash quantity
 Fly ash particle size & its distribution
Contd …
International
seminar
optimization
optimization
&blended coal“
combustionoftuning
27 01 2013 282701 2013
– 28 July12
Emissions
SO2 emission can be reduced by blending
 High sulphur coal with low sulphur coal

 High sulphur coal with a coal which captures a greater
proportion of the sulphur in the ash
NOx emissions are additive under staged combustion
condition
NOx concentrations can be higher in short residence

time boilers & additive under higher residence time
boilers
International
seminar
optimization
optimization
&blended coal“
combustionoftuning
27 01 2013 282701 2013
– 28 July12
Broad guidelines for coal blending

Coals must be compatible for blending
Blended coal characteristics should be closer to design coal
Coals selected for blending should have very little variation in volatile
matter content
Blending of coal before mills should not be adopted if the volatile
matter and ignition characteristics of the coals vary as this may lead to
firing in mill itself
If the ignition characteristics vary significantly, pulverising can be done
in a separate mill and level firing in the furnace may be practiced and
the mill outlet temperature need to be adjusted to avoid fire hazards.
International
seminar
optimization
optimization
&blended coal“
combustionoftuning
27 01 2013 282701 2013
– 28 July12
Compatibility in Blending of coals
Blended coals should be preferably of

Same rank
Same ash chemistry
Same petro graphic constituents
International
seminar
optimization
optimization
&blended coal“
combustionoftuning
27 01 2013 282701 2013
– 28 July12
Blending of coal in India
Indian coals are blended mostly with following imported coals

Indonesian coal
South African coal
Australian coal
(This is based on the current international coal market scenerio)
Majority of the plants decide the blending proportions

depending upon the availability of the coal
International
seminar
optimization
optimization
&blended coal“
combustionoftuning
27 01 2013 282701 2013
– 28 July12
Parameters Unit Indian Coal Australian Coal Indonesian Coal South African Coal
Proximate Analysis Fuel Analysis(typical)
Fixed Carbon % 25.0 52.0 29.66 55.39
Volatile Matter % 22.0 33.0 31.0 22.83
Total Moisture % 13 9 35 8.0
Ash Content % 40.0 12 4.34 13.78
HHV (kCal/kg) 3300 6520 4100 6260
Ultimate Analysis
Carbon % 32.16 83.5 44.06 64.67
Hydrogen % 3.10 5.2 3.0 3.92
Sulphur % 0.40 0.6 0.08 0.43
Nitrogen % 2.00 1.8 0.97 1.17
Oxygen % 8.51 8.9 12.55 8.03
Moisture % 13.00 3 35.0 8.0
Ash % .8 12 4.34 13.78
HGI 0.03 50 53 53
Ash Fusion Temperature
IDT 0C 1100 1450 1150 1530
HT 0C 1400 1500 1200 1560
FT 0C 1300 1500 1250 1560
International
seminar
optimization
optimization
&blended coal“
combustionoftuning
27 01 2013 282701 2013
– 28 July12
Effect of Blended Coal Firing

Indian coals and Imported coals have distinctly different characteristics
Blending has to be done cautiously and observing the boiler for any adverse
performance.
Based on the feedback from earlier trials, up to 30% (by weight) of imported
coal can be blended with Indian coal.
The moisture in the imported coal is of great concern and hence, depending
on the type of blending, the hot air temperature is to be maintained.
Slagging/fouling characteristic of blended coal is an important factor. The
characteristics of ash are to be studied to arrive at the slagging potential.
High slagging coals will impose a limitation in reaching the rated capacity.
When slagging coals are blended, it is necessary to conduct site trials, to
establish a safe percentage of blending.
Workshop on Coal“Combustion optimization

Blending, Imported coal firingof&blended coal“
combustion tuning 30 02
27 01 2013 27 – 28 July12
Effect of fuel change in boiler performance during operation
Boiler designed Difficult to obtain

Firing Very low ash
for high ash rated SH/RH steam
Non-slagging coal
Low or medium temperature
slagging coal (Because of larger furnace)
Boiler designed
Firing Abnormal
for low or medium
Slagging/fouling Coal SH/RH Spray
slagging coal
International
seminar
optimization
optimization
&blended coal“
combustionoftuning
27 01 2013 282701 2013
– 28 July12
CRITERION FOR ACCEPTANCE OF BLEND PROPORTION
The blend proportion was considered acceptable under following

conditions:
Deposits on heat transfer surfaces of water wall and convection pass
should be fully removable.
Full regain of heat flux after wall / soot blowing.
Lesser rise in furnace exit gas temperature and temperature across
convection pass heat transfer surfaces in between wall/soot blowing
cycles due to slagging and fouling of the coals respectively.
No abnormal increases in
- SH / RH Spray
- NOx, CO emissions
- Unburnts in bottom and fly ash
- Acid dew point temperature of the flue gas at air heater outlet
Workshop on Coal“Combustion optimization

Blending, Imported coal firingof&blended coal“
combustion tuning 30 02
27 01 2013 27 – 28 July12
Blending of Coal –Indian Experience
International
seminar
optimization
optimization
&blended coal“
combustionoftuning
27 01 2013 282701 2013
– 28 July12
Blending of Coal –Indian Experience

Indian coals have been blended and sucessfully fired in BSES-Dahanu
2x250MW,KPCL/Raichur#4 210MW, Sikka 110MW, Jindal Steel plant#2, etc.,
The 100% imported coal firing has been adopted in Trombay 500MW and
250MW units.
Following are the feedbacks
The Specific coal consumption has been reduced
Aux power has come down due to reduction in no of mills in operation
Maintenance cost reduced due to lesser ash content
However when the high moisture imported coal is used in boiler designed for
low moisture indian coal, there is an Efficiency reduction in the boiler.
Also fouling and deposition problems faced.
International
seminar
optimization
optimization
&blended coal“
combustionoftuning
27 01 2013 282701 2013
– 28 July12
BHEL Boiler Fired with imported Coals other

than Design coal
Blended firing –REL Dahanu, JSL Duburi, Raichur (Trial)
Elevation firing-Raichur, Bellary, Gandhinagar, Tuticorin, etc.,
100% imported coal firing –Tata Trombay, Trial conducted at Raichur
International“Combustion
seminar on “Combustion
optimization of
optimization
blended coal“
of blended coal“ 30 02
27 01 2013 28 01 2013
REL Dahanu 2 x 250MW
• Manufacturer : BHEL
• Type : Natural circulation, Balance draft, Double pass, Single Drum,
Single reheat, Direct Pulverised coal fired Water Impounded
Bottom.(Gas firing and Gas regulating Provision for future).
• Boiler Design Pr & Temp. : 182.5 Kg/cm2 & 540 O C
• Type of Firing : Tilting Tangential
• Steam Generation Capacity : 805 T/Hrs. at 100% BMCR
• Mill Type : BBD 4772, 3 numbers(2 for normal operation)
• Mill Capacity : 84.8 T/Hrs. (98.7 T/Hrs. for worst coal)
• Inlet Coal size : 25 mm
• Outlet coal size : 200 mesh (70% pass through)
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optimization of
optimization
blended coal“
27 01 2013 28 01 2013
Boiler Design coal

Unit Design
Fixed Carbon % 31.00
Volatile Matter % 19.00
Moisture % 10.00
IM % 4.00
Ash % 40.00
Carbon % 39.00
Hydrogen % 2.50
Oxygen % 7.50
Sulphur % 0.40
Nitrogen % 0.70
Coal GCV kcal/kg 3700.00
C in BAH % 3.00
C in Fly Ash % 0.71
27
optimization of
optimization
blended coal“
27 01 2013 28 01 2013
Initial Experience with Indian raw coal

• Boiler at DTPS are designed for Indian raw coal of GCV-3700 Kcal/Kg.
• Designed coal consumption is 152 T/H for 250MW.
• During 1999, raw coal quality deteriorated so much (GCV 3300 Kcal/Kg) and not able to generate
250 MW load even with high coal consumption 180 TPH.
• This increase in coal consumption having following disadvantages:
1. ESP performance even with 99.98% efficiency , average opacity was maintaining on higher side
120 mg/Nm3 which is high, since the plant falls under environmentally sensitive zone.
2. PLF graph start dropping.
3. Reliability and availability of equipment's get reduced with rise in failure rate of boiler pressure
parts (tube failure). coal mill, feeders & conveyors.
29
optimization of
optimization
blended coal“
27 01 2013 28 01 2013
Adoption of Imported coal at DTPS

• 1st phase of coal blending started in 1999 with imported coal which had GCV of 6100
Kcal/Kg, ash=1.2%, total moisture=6 to 8% and Sulphur=0.069, VM=36.45%.
• Blending carried out with ratio 90% Indian raw coal and @10% imported coal keeping
GCV around 3700 Kcal/Kg. Then blending ratio gradually increased to 75:25 and Max
blended coal GCV kept around 4200 Kcal/kg
The results were remarkable with following parameters.
1. Coal quantity reduced to 145 to 150 TPH & unit load reached up to 260 MW with
much better boiler parameters.
2. ESP loading decreases and TPM reduced to 80 mg/Nm3 giving much relief to DTPS.
30
optimization of
optimization
blended coal“
27 01 2013 28 01 2013
Adoption of Imported coal at DTPS

• 2nd phase of coal blending started when acute shortage of Indian coal felt in 2004
end .
• 2005 onward, DTPS started imported low GCV , high moisture and high VM coal
which can be used as a substitute of Indian coal.
• Certain blending practices are adopted at DTPS to counter-balance any chances of

non-homogenous mixture bunkered in view of high GCV & moisture of all
imported coal.
• Certain operational practices are also adopted to safe guard the mill in case there
is any chance of improper blending in view of high GCV, high moisture & high VM.
31
optimization of
optimization
blended coal“
27 01 2013 28 01 2013
Blending mechanism
• Blending is a procedure where in two/three different grades of coal are mixed uniformly
in predetermined proportion for achieving desired calorific value
• Blending of coal is done on conveyor and as per requirement
Two /three different grades of Coal are lifted from separate locations. Lifting rates / flow
is predetermined and is monitored through Belt Scale by the operator as well as from
Control room.
• These different grades of coal are fed on a single conveyor (three locations). There are
minimum two transfer points where these three grades of coal get mixed uniformly
(due to free fall of about 8-10 meter) before being fed to bunker.
• During bunkering, there is another free fall of coal. The process itself ensures proper
blending of two/three coal
32
optimization of
optimization
blended coal“
27 01 2013 28 01 2013
Types of coal used
• Indian Row coal “F” grade GCV varies from 3300 to 3700 Kcal/Kg.
• Indian Washed coal GCV varies from 3800 to 4100 Kcal/Kg.
• Imported coal having low GCV (around 4100Kcal/kg) and it’s a substitute of
Indian coal.
• Imported coal having medium/High GCV are around 5200 and 6100 Kcal/kg
respectively.
• After blending of two or three types of coal the blended coal ratio is
maintained around GCV 4200 Kcal/Kg
33
optimization of
optimization
blended coal“
27 01 2013 28 01 2013
Coal Parameters
Type of Raw coal Washed High GCV Medium LOW GCV Blended
Coal/ coal Imported GCV Imported coal
Parameters coal coal
TM 11.-12 15.19 7-9 23.18 36.12 18-19
Ash 40-46 32.18 17.13 4.16 3.17 26
VM 18-19 20-24 22.57 35 32.06 24-27
FC 20-25 27-30 52.54 37.95 28.65 28-30
GCV 3300-3700 3800-4100 6000-6100 5200-5400 4100-4600 4000-4200
optimization of
optimization
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27 01 2013 28 01 2013
Boiler Performance
Operational benefits with blended coal firing:
• Reduction in coal consumption:- Specific coal consumption reduced from 0.62 to 0.56
kg/kwh.
• Reduction in Ash generation:- Around 10%. Ash generation reduced. This gives benefits
in reduction in auxiliary power consumption for ash handling plant. Deashing cycle time
reduced to 8 hrs. from 12 hrs.
• Reduction in maintenance of Ash handling equipment:- Reduction in ash generation has

resulted in lesser erosion of ash handling equipment. This has resulted in reduction in
maintenance cost of ash handling equipment.
• Reduction in boiler auxiliary current:- Since Average GCV of coal has improved, less
amount of coal is required for achieving full load (260 MW). Mills loading and ID, FD &
PA fans loading reduced substantially.
35
optimization of
optimization
blended coal“
27 01 2013 28 01 2013
Boiler Performance
• Reduction in maintenance of Boiler pressure parts:- As there is less ash generation in
Boiler, tube leakage due to ash erosion and flue gas erosion has reduced.
• Reduction in ESP loading:- due to reduction in coal consumption, ESP loading has
reduced and its performance increased.
• Improvement in Environmental performance:- Due to reduction in coal consumption

there is substantial reduction in stack emissions TPM from stack. Achieved daily average
value of @ 80 Mg/Nm3 against 120 Mg/Nm3.
• Reduction in APH flue gas outlet temperature:-, APH flue gas outlet temperature
reduced by around 10 deg.C (145 to 135 Deg.C). Reduction in coal consumption.
• Reduction in DM water consumption:- Due to use of washed coal, frequency of water

wall & LRSB soot blowing has reduced to half.
36
optimization of
optimization
blended coal“
27 01 2013 28 01 2013
KPCL
Raichur TPS unit-4, 210 MW
optimization of
optimization
blended coal“
27 01 2013 28 01 2013
Design parameters of Boilers at RTPS
Sl. Particulars U # 1 to U # 7 Unit # 8

No
1 Unit Rated Capacity- MW 210 250
2 Manufacturer BHEL BHEL
2 Steam Generating Capacity- TPH 670 810
3 Drum Pressure Ksc 160 169
4 SH temp. ° C 540 540
5 RH temperature ° C 540 540
6 Tangentially fired with Burner tilt +30° to -30° +30 ° to -30°
Design Coal Properties of RTPS Boilers
Sl. Particulars Measuring U#1 U#3 U#4 U#5 U#7 U#8

No Unit &2 &6
1 CV of Coal Kcal/kg 4700 3650 3500 3500 3500 3500
2 Total % 8 8 10 10 10 10
Moisture
3 Ash in coal % 28.0 40.0 40.0 40.0 40.0 42.7
4 Volatile % 26.0 21.7 21.7 21.19 21.19 22.60
Matter
5 HGI 44 45 45 45 45 45
RTPS -coal linkage
Source Annual contracted quantity Lakh MT

Sinagareni Coal Company Ltd 30.10
Western Coalfields Ltd 24.75
Mahanadi Coal fields Ltd 21.40
“Combustion optimization of blended coal“ 30 02

27 01 2013
Coal Blending at RTPS :-
Coal blending was taken up by KPCL initially during the year 2001.
Blended Coal firing involved following Steps :-
1) Assessment of quality of coal varieties to be blended

2) Performance of Mills
3) Performance of Boiler
4) Post combustion aspects
PROXIMATE ANALYSIS
COAL SOURCE
Description Unit PT Kaltim Mancherial New Sasti Yellandu

(Indonesian) (SCCL) (WCL) (SCCL)
Total Moisture % 10.90 11.40 11.00 9.40

Air Dried Moisture % 6.90 4.90 3.80 1.90
Volatile Matter % 39.70 27.20 23.80 26.20
Ash % 7.10 34.50 35.10 32.90
Fixed Carbon % 46.30 33.40 30.10 31.50
GCV(ADB) Kcals/Kg 6476 4480 3810 4220
HGI 46 53 60 60
Total % 0.50 0.73 0.88 0.38
optimization of
optimization
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27 01 2013 28 01 2013
Findings from the study

Based on the results of the trials conducted with Sasti, Yellandu, Mancherial coals and their blends in Unit-3 of RTPS during
February 2001, the following conclusions could be arrived.
Spontaneous Ignition:
Spontaneous ignition may not be a problem for carrying out blended firing of Indonesian coal with Indian coal.
Milling: Milling of blends is not reducing the fineness.
Flame Stability: The flame stability performance of blends could be rated to be good and equal to that of Indian coal.
Carbon Loss: Combustion performance improves on blending.
Furnace Heat Absorption:

Furnace Temperature and Incidental Radiation Heat flux Profile:
Considering the furnace temperature and heat flux values, blended coal firing is considered advantageous for Sasti and
Yellandu coals. In case of Mancherial coal though the heat flux values were lower for the blend, but the overall performance
was not adversely affected.
Absorbed Heat flux Trend :

The fluctuations in heat flux are lesser during firing blends compared to that during firing Indian coal
Furnace Outlet Temperature (FOT) Trend:
The furnace outlet temperature is lower indicating better furnace absorption.
Water Wall Deposit Cleanability

Blended firing has not resulted in any hard deposits that are difficult to remove.
Super Heater Spray:

In general, blended firing results in lesser super heater spray than with firing Indian coal alone indicating better furnace heat
absorption.
optimization of
optimization
blended coal“
27 01 2013 28 01 2013
Trombay Thermal Power Station

Trombay Thermal Power Station

Capacity : 1580 MW
Unit Year of Capacity Unit Efficiency Fuel Used

Comm.. (MW) (%)
UNIT 5 1984 500 36 Coal, Oil and Gas
Unit 8 2009 250 37 Coal
42
Different Coals used at trombay
Ash Sulphur
Source CV Range Range Range
K Cal/Kg % %
Australia 6000~6200 8~12 0.6~1.6
South Africa 6000~6400 1.0~2.0 0.6~1.6
China 6000~6200 8~20 0.25~1.0
Russia 6000~6200 8~20 0.25~1.0
Indonesia 4800~5200 1~5 0.1~0.15
Indonesian Coal properties
44
Indonesian Coal properties
45
Coal Analysis of import coal
Proximate Analysis
Fixed Carbon 41 %
Volatile Matter 43 to 45 %
Inherent Moisture 9 to 14 %
Ash Content 1 to 2 %
Calorific Value 5700 to 6050
(Air Dried Basis (Kcal/Kg))
Ultimate Analysis (Dry Ash Free basis)
Carbon 72 to 74 %
Hydrogen 4.5 to 6 %
Sulphur Content 0.1 to 0.12 %
Nitrogen 0.8 to 1.5 %
Oxygen Balance
Ash Content 1 to 3 %
Total Moisture 25 to 33 %
Ash Analysis
Silica as SiO2 30 to 33 %
Aluminium as Al2O3 19 to 22 %
Iron as Fe2O3 15 to 21 %
Manganese as Mn3O4 0.2 to 0.3 %
Calcium as CaO 10 to 20 %
Magnesium as MgO 2 to 4 %
Sodium as Na2O 0.2 to 0.50 %
Potassium as K2O 0.8 to 1.0 %
Titanium as TiO2 1 to 1.5 %
Sulphate as SO3 8 to 11 %
Impacting Factors
• Operational Aspect
• Maintenance Aspect
• Performance Aspect
• Environmental Aspect
Operational Aspect
• Explosion in the PA Duct

– 3 Major explosions in 2003 & 2004
– Remote operated inert steam valves installed
– Zero explosions achieved - Purging adopted during Mill starting /
stopping
• Mill Air Temperature Sudden Increase
– PA inlet temp restricted to 240 deg C and Mill air temp to 60 deg
C
• Deluge of Rejects (during monsoon)
– MPSP system introduced on all Mills
– PJHS system converted to SJA system
• Higher FGET
Explosion in the PA Duct – 4-May-2003
AA014 FA005
FD A Disc Fur Pr
380 120
370 100
95.8
360
80
350
60
340 339
40
330
20
320
-5 0
310
-20
300
-41.6
290 -40
288.3
280 -60
6:23:00
6:23:15
6:23:30
6:23:45
6:24:00
6:24:15
6:24:30
6:24:45
6:25:00
6:25:15
6:25:30
6:25:45
6:26:00
6:26:15
6:26:30
6:26:45
6:27:00
Explosion
Explosion Vents
Explosion vents for duct failures
CO monitoring is also done as a lead measure for reducing mill duct explosion
53
Higher FGET
• Measures Carried out:

– Equipment Modifications
• 100 % replacement of Baskets
• Reverse rotation of RAPH
• Partial blanking of PA Sector
– Operational Practice
• Regular LRSB operation (every shift instead every day)
• Polarchem dosing in the Furnace
• Optimise Excess Air (2.5 %)
Maintenance Aspect
Mill related
• Lower Wear of Rollers & BRS
– Wear rate 6 mm / year
• Lower Wastage of Mill components
– Fewer replacements
• Increased Coal Pipe Joint Leaks
– Due to increased instances of Mill Temp rise
During Monsoon
• Frequent hosing of Chokes and flushing of Separator Body
– To reduce down time
– Feeder Outlet pipe modified
– Feeder Outlet pipe Heat Traced
– Feeder Outlet Chute Cold Metal Lined
• Choking of PC Pipe
– 5 chokes in last 2 years
Maintenance Aspect - contd
Others
• Boiler Washing
– During outages Furnace requires around 12 hrs washing
– Second pass requires around 1.5~2 days washing
• ESP Stream Washing
– Washing frequency of every stream increased to once in 4
month (earlier once in 2 years)
• FGD GGH Element Choking
– 100 % enameled Elements replaced
– Monthly in-line washing, and off-line washing with HP jet
being carried out
Performance Aspect
• Higher FGET
– High Moisture leading to higher Furnace Exit Temp
– Lower Mill Air Temperature
• Higher Reheat Spray (~7.5 Kg/sec)
• Frequent Change over of Mills
– Higher Heat-rate
– During Monsoon 7th Mill Operation leading to further
increase in heat rate
• Formation of Slags
– Lower Ash Fusion Temp
Environmental Aspect
• Lower Ash handled

• Lower Sulphur emission
• Higher Fines / Dust
• Mill Explosions
– Safety of Working Personnel
– Safety of Equipment
JSL Captive Power Plant,

Duburi Unit 2, 125 MW
optimization of
optimization
blended coal“
27 01 2013 28 01 2013
Imported coal firing, June 2012
Manufacturer : BHEL
Design : Indian coal of calorific value 3200 kcal/kg.
Type of Firing : Tilting Tangential
Imported coal : Indonesia
Four elevations were run with 20% imported coal : 80% Indian coal
Different blend ratios were tried in the individual mills
optimization of
optimization
blended coal“
27 01 2013 28 01 2013
Observations
• No clinkering observed during testing
• No mill fire observed
• SH/RH temperature is achievable
• Mill outlet temperature could be maintained above 55°C for imported coal
• Specific fuel consumption reduced reasonably with good quality imported coal
• With 100% imported coal in one mill (XRP 803-max capacity 36.5TPH), a maximum
coal flow of 26.7 TPH could be achieved with outlet temperature not below 55°C
• Restricting factors are maximum permissible elevation heat loading and mill outlet
temperatures
• The high quantity of moisture adds to more fuel moisture loss and reduction in boiler
efficiency resulting in more coal consumption.
• Cost of operation (cost per unit generation) is comparable for both the coals due to
the higher moisture present in imported coal.
optimization of
optimization
blended coal“
27 01 2013 28 01 2013
CONCLUSIONS
Blending of coals expected to grow over the next decade as electric
utilities attempt to
 Meet coal shortage in the country
 Reduce cost
 Meet SO2 emission limits
 Improve combustion performance of their coals
All aspects of a blend’s behaviour & its effect on all components of
the power stations, from the stock pile to the stack, should be
considered before the most appropriate blend composition is chosen
Contd …
optimization of
optimization
blended coal“
27 01 2013 28 01 2013
CONCLUSIONS
When the blend ratio is around 30:70 for imported coal:indian coal the results are
found to be comfortable based on the trials carried out.
The impact of blending coals of different hardness on the finalize distribution and
compositional distribution of the pulversied coal is still not understood
Non - additive properties make blend evaluation for power generation inherently
complex
Traditional indices for ash deposition are unreliable when applied to blends
More work is required on understanding how the inorganic components of coals in the
blend interact & how it affects ash behavior, including its emissivity, reflectivity &
thermal conductivity
optimization of
optimization
blended coal“
27 01 2013 28 01 2013
optimization of
optimization
blended coal“
27 01 2013 28 01 2013

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Bharat Heavy Electricals Limited, Tiruchirapalli

“Combustion optimization of blended coal“ 27 02 2013

Blending & Its effect on boiler design

Coals can be Blended and successfully fired in any new

Coal Properties Affecting Boiler Performance of Blended Coal

Effect of Moisture on Boiler performance

Effect of Volatile matter on Boiler performance

Fuel with ash characteristics leading to slagging and fouling requires a

The ESP selection is mainly based on the quantity of ash generated.

When the Ash % of the blended coal is low..

 Furnace size could be reduced

 SH/RH & Economiser heat transfer area could be reduced by adopting

 ESP size could be reduced

Effect of Fixed carbon on Boiler performance

Fuel ratio = Fixed carbon/Volatile matter

When the Fuel ratio % of the blended coal is High…

When the Fuel ratio % of the blended coal is low…

Effect of Calorific value on Boiler performance

When the Calorific value differs substantially, the % blending should

Careful Field trials are mandatory before increasing % of blending

Effect of grindability index on Boiler performance

Grindability index of blended coal is Not proportional to weighted Grindability

Indiscriminate blending of coals with different Grindability index will lead to

But Pulveriser performance more closely resemble that of harder coal

Suggested to restrict the difference in Grindability index between the constituent

Segregation of ash during pulverising & its properties

Ash deposition in a boiler is an extremely complex

During blending the combination of Iron, Sulphur, Sodium,

Coal quality influences particulate, SO2 and NOx emissions

A coal blend affects ESP performance primarily through the

 Fly ash resistivity

 High sulphur coal with low sulphur coal

NOx concentrations can be higher in short residence

Broad guidelines for coal blending

Compatibility in Blending of coals

Blended coals should be preferably of

Blending of coal in India

Indian coals are blended mostly with following imported coals

Majority of the plants decide the blending proportions

Effect of Blended Coal Firing

Workshop on Coal“Combustion optimization

Effect of fuel change in boiler performance during operation

Boiler designed Difficult to obtain

CRITERION FOR ACCEPTANCE OF BLEND PROPORTION

The blend proportion was considered acceptable under following

Workshop on Coal“Combustion optimization

Blending of Coal –Indian Experience

Blending of Coal –Indian Experience

BHEL Boiler Fired with imported Coals other

Blended firing –REL Dahanu, JSL Duburi, Raichur (Trial)

Elevation firing-Raichur, Bellary, Gandhinagar, Tuticorin, etc.,

100% imported coal firing –Tata Trombay, Trial conducted at Raichur

• Type : Natural circulation, Balance draft, Double pass, Single Drum,

Single reheat, Direct Pulverised coal fired Water Impounded

Bottom.(Gas firing and Gas regulating Provision for future).

• Boiler Design Pr & Temp. : 182.5 Kg/cm2 & 540 O C

• Type of Firing : Tilting Tangential

• Steam Generation Capacity : 805 T/Hrs. at 100% BMCR

• Mill Type : BBD 4772, 3 numbers(2 for normal operation)

• Mill Capacity : 84.8 T/Hrs. (98.7 T/Hrs. for worst coal)

• Inlet Coal size : 25 mm

• Outlet coal size : 200 mesh (70% pass through)

Boiler Design coal