COAL MILL FIRING SYSTEM

Inderect Firing
Existing Design : per unit Power Plant of 35 MW (Gross Out Put)
PC Boiler with Direct Firing
Boiler Capacity : 35 TPH
Design NPHR : 3083 kcal /kwh
Design Coal HHV (AR) : 4.100 Kcal/kwh

3.083
Coal flow rate = x 35 TPH
4.100

= 26,32 TPH

Proposed design of NEM has configuration :

* Direct firing: Each boiler with 3 units of Coal Mills, 2 in operation, 1 standby
* Mill capacity = 14 TPH each
Proposed design of REKIN has configuration :
* In-Direct firing: Two boilers with 3 units of Coal Mills, 2 in operation, 1 standby
* Mill capacity = 31.4 TPH each
 Inderect Firing
Constraints :

1. Ramping – Up requirement = 3 % load/ minute

= 1 MW / minute
Converted to Coal Consumption during acceleration is =

NPHR
= x 1 MW / minute
Coal HHV

3.083
= x 1 Ton / minute
4.100

= 0,75 Ton/minute

a) Ramping – Up is From Turn – Down Ratio (40 % Load) To 100 % load

or from 14 MW to 35 MW.
Rumping – Up time 14 35 = 21 minutes
or PC needs = 21 x 0,75
= 15,75 Ton
b) Ramping – Up from inhouse power ( 5 MW) to full
load (35 MW) :
Ramping – Up time 5 35 = 30 menit
Or PC needs = 30 x 0,75
= 22,5 Ton

2) Mill Maintenance :
Practically Mill need maintenance for 1 shift (8 hours)
per week (7 days).
We design spare time for mill maintenance at
2 h/day or 14 h/week. So the operating hour is
(24 – 2) h/day = 22 h/day
 Mill Sizing
Indirect Firing for PC Boiler Mill Configuration follow this scheme :

Boiler Boiler
1 2

PC PC PC
PC
Feeder A Feeder B Feeder B
Feeder A

Pulverised coal Pulverised coal

Bin 1 Bin 2

1 2 3
NOTE :
Coal Mill Run 2 unit
Stand by 1 unit Coal Mill
 Coal Consumption
2 units Boiler Ramp-up to Full-Load
= 2 x 26,32 TPH
= 52,64 TPH at PC Coal

2 Units Boiler Ramp– up 5MW to 35MW

= 2 x 22,5 ton/ 30minutes
= 45 ton/30minutes

Coal taken from PC bins during ramp – up for 2 unit boiler is :

52,64
= 45 ton/30minutes - ton/30 minutes
2

= 18.68 ton / minutes

 Mill Sizing
Mill configuration: 3 units, 2 operation, 1 standby
• Minimum mill capacity of 13,15tph is needed.
• After ramp-up two mills will run to fill the PC bins of 18,68 ton while
supplying boiler operation.
• Coal needed from PC bin each boiler will be
18,68 ton
= 9,34 ton
2
• PC bin is design to have retention time of 6 hours so that the minimum bin
capacity is 60 ton/unit boiler.
• Maximum time to fill PC to bin after ramp-up is 1 cycle of cement plat
start-up cycle, ie. 300 minutes or 5 h.
• So, based on 24h continues operation the minimum coal mill capacity is
26.32 + (9.34/5) or 28.2 tph
 Mill Sizing
Mill configuration: 2 units with 2 operation
• Based on 24h continues operation the minimum coal mill
capacity is 26.32 + (9.34/5) or 28.2 tph
Mill Maintenance :
Practically Mill need maintenance for 1 shift (8 hours) per week
(7 days).
We design spare time for mill maintenance at
2 h/day or 14 h/week. So the operating hour is
(24 – 2) h/day = 22 h/day
Coal Mill Size:
24/22 x 28.2 tph = 30.75 tph
So the minimum coal mill capacity is 30.75 tph
 Mill Sizing
Indirect Firing for PC Boiler Mill Configuration follow this scheme :

Boiler Boiler
1 2

PC PC PC
PC
Feeder A Feeder B Feeder B
Feeder A

Pulverised coal Pulverised coal

Bin 1 Bin 2

1 2
NOTE :
Coal Mill Run 2 unit
Stand by 0 unit Coal Mill
 Equipment List

1. Coal Mill = 2 x 31 TPH

2. Raw Coal Silo = 2 x 150 Ton (5h retention)
3. PC Bins = 2 x 60 Ton
4. PC Feeder = 4 x 15 TPH
5. Safety Equipment (CO2 inert) for 2 unit Boiler.