Power Plant Operation And

Performance Optimisation
Objectives

• Safety Of Personnel And Equipments

• To Protect Equipments Form Failures

• To Product Steam At The Required Parameters

And Quality

• To Achieve Optimum Efficiency And Economy

During Operation
 Heat Balance for Steam Process
Energy Input
Feed Water Steam @ Pressure
P1
Usefull
Energy Input Steam Process Energy
Air & Fuel Output
P1

Energy Energy Energy

Loss Loss Loss
Flue Blow Down Due to Piping
Gas Water Friction Loss
Equipment etc.

Energy Output = Energy Input - Losses

 PLANT EFFICIENCY & HEAT RATE

482.8 Mkcal/hr 420 Mkcal/hr 180.6 Mkcal/hr 172 Mkcal/hr

boiler 210
T
MW 200 MW
120.7 t/h auxpower 10 MW
4000 kcal/kg

87.0 % 2000 kcal/kwhr 43.0 %

2299 kcal/kwhr 37.4%

2414 kcal/kwhr 35.6 %

 Summary of losses in a boiler

L2 Moisture loss % 6.523

L1 Dry gas loss % 5.542
L3 Combustible loss % 1.453
13.518
L5 Radiation loss % 0.270
L4 Air moisture loss % 0.200
L6 Sensible heat of ash % 0.415
L8 Carbon monoxide loss % 0.065
L7 Mill reject loss % 0.049
0.999

L Total % 14.517

E Efficiency % 85.483
100 - L
 Summary of losses in a boiler
controllable
L1 Dry gas loss % 5.542
L3 Combustible loss % 1.453
L8 Carbon monoxide loss % 0.065
L7 Mill reject loss % 0.049
7.109
un -controllable
L2 Moisture loss % 6.523
L5 Radiation loss % 0.270
L4 Air moisture loss % 0.200
L6 Sensible heat of ash % 0.415
7.408

L Total % 14.517

E Efficiency % 85.483
100 - L
Factors Influencing Various Losses
Loss Factor

Dry Gas Loss Flue Gas Temperature

Excess Air Level In Flue Gas
Fuel Analysis

Loss Due To Moisture Formed Hydrogen Content In Fuel

From hydrogen in Fuel Flue Gas Temperatuare
Fuel Analysis

Loss Due To Fuel Moisture Moisture Content In Fuel

Flue Gas Temperature

Loss Due To Air Moisture Huimidity Of Combustion Air

Excess Air Level
Flue Gas Temperature

Radiation & Convection Loss Insulation Of Boiler

Mill Rejet Loss Reject Rate

CV Of Reject

Unburnt Carbon Loss In Ash Unburnt Carbon In Fly / Bottom Ash

Fuel Analysis

Sensible Heat Loss In Ash Ash Temperature

Fuel Analysis
Boiler Losses Operator Controllable
Efficiency
Dry gas Loss
Excess air
Exit gas temperature
Air ingress
Fouling
Tempering air
Tramp air
Carbon loss
Excess air
Air regime
Mill fine ness
Factors Affecting Dry Gas Loss

1 Coal
Moisture
Carbon
Gross CV

2 Air temperature entering AH

Ambient
SCAPH

3 Gas temperature
AH leakage
AH entering air temperature
AH entering gas temperature
Boiler load
FW temperature
X ratio of AH
Tempering air
Air ingress

4 Gas quantity
Excess air
AH leakage
 Various methods to control carbon loss
• Good burner maintenance

• Ensuring consistent mill fineness

• Proper secondary air adjustment

• Reducing primary air to the minimum most possible

• Cutout oil support at higher loads where coal flame is

stable as oil preferentially deplete o2 in the area and
reduces ‘o2 ‘ for coal particles to burn

• Check coal property and tune combustion

• Keep boiler heat transfer surface clean so that losses can

be reduced thus reducing the coal input
FACTORS AFFECTING AUXILIARY POWER

ID FANS
AH LEAK
GAS TEMPERATURE
DUCT LEAKAGES
EXCESS AIR
LOAD/ PLANT HEAT RATE
DRAUGHT LOSS
AH CHOKING
FD FANS
AH LEAK
WIND BOX PR.
EXCESS AIR
LOAD/ PLANT HEAT RATE
PRESSURE LOSS
AH CHOKING
SCAPH CHOKING
PA FANS
AH LEAKAGE
PA HEADER PR.
MILL AIR FLOW
PRESSURE LOSS
AH CHOKING
MILL
COAL QTY.
GCV
LOAD/ PLANT HEAT RATE
COAL
MOISTURE
HGI
COAL FINENESS
MILL CONDITION
Capacity Reduction in a Boiler

Fuel input
Low cv coal
Milling capacity
Grinding capacity
Drying capacity
Carrying capacity
Drive capacity
Draught system
ID fan limitations
Pressure drops high
AH choking
Chimney back pressure high
High volume
AH leakages
Duct leakages
High gas temperatures
Worn out impellers

Metal temperatures high

High spray requirements
Fouling of surfaces
 Effect of boiler parameters
on thermal cycle

SH outlet pressure

SH outlet temperature

RH outlet temperature

RH spray

SH spray

Blowdown

Auxiliary Steam
 Effect on Plant Heat Rate
Due to Boiler Parametars

For a 500 MW unit

kcal/hr
10 ° C drop in MS temperature 9.6

10 ° C drop in RH outlet temperature 6.6

1 % increase in RH pr. drop 3

(% of inlet pr.)

Decrease in throttle pressure by 1 bar 1.2

SH spray increase by 1 % 0.6

RH spray increase by 1 % 6
 Effect Of Coal Properties On Bituminous
Coal Fired Boilers

Analysis Consequence of Transgressing limits

Moisture
(as received) - Drying Limitations
- Reduced Mill output
- problem in transfer chute conveying system
- Arching, Clinging, bridging in coal bunker

Ash - Reduced Mill output & Boiler load

limitations
 Effect of Coal Properties on Bituminous
Coal Fired Boilers (Contd…)

Analysis Consequence of Transgressing limits

Volatiles ( Dry mineral

Matter free) - Oil support necessary even at higher
loads
- Higher Combustion in Ash

Sulphur (as received)

- problems in ESP
- Increased SO2 emission
 Effect of Coal Properties on Bituminous Coal
Fired Boilers (Contd…)

Analysis Consequence of Transgressing limits

GCV (as received) - Reduced Mill output and

Boiler load limits

Grindability index - Reduced Mill output and

Boiler load limits
 Effect of Coal Properties on Bituminous
Coal Fired Boilers (Contd…)

Analysis Consequence of Transgressing limits

Slagging - Increased furnace deposits &

increased frequency of soot-
blowing or beyond the capability of
normal soot-blowers
Fouling - possibility of blockage in
convective pass
Sodium &
Potassium oxides - Reduced ESP performance due to
high ash resistivity
 Factors Affecting Furnace
Stability / Combustion

• Raw Coal Feeding System

• Pulverised Coal Fineness
• Pulverised Coal Distribution
• PA Flow
• PA Pressure
• Coal Quality Etc.
 Factors Affecting Furnace
Stability / Combustion (Cont)
• Mill Inlet / Outlet Temperature
• Total Air
• SADC
• SA Temperature
• Burner Nozzle Condition
• Burner Nozzle Position
INDIAN COALS
Vs
OTHER COALS
 DETERIORATION OF COAL QUALITY AVAILABLE
FOR POWER GENERATION OVER THE PERIOD
1970’s 1989’s 1990’s
PROXIMATE ANALYSIS
FIXED CARBON % 36.5 32.4 25.0
VOLATILE MATTER % 25.5 21.6 18.0
MOISTURE % 10.0 16.0 12.0
ASH % 28.0 30.0 45.0
HHV kcal/kg 4750 4050 3000
HGI 50 50 50
 INDIAN COAL Vs USA COAL

PARAMETER INDIAN UNIT USA UNIT

210 MW 500 MW 210 MW 500MW
HEAT DUTY mcal/h. 454 1070 454 1070
FUEL FIRED mkcal/h. 520 1215 520 1215
HHV kcal/kg. 3800 3800 6000 6000
QUANTITY OF FUEL t/h. 137 320 87 202.5
AVERAGE ASH CONTENT % 40 40 8 8
QUANITY OF ASH t/h. 55 128 7 16.2
 AMOUNT OF COAL / ASH HANDLED OVER
THE PERIOD

HHV kcal/kg 4750 4050 3000

UNIT RATING mw 210 500 210 500 210 500
ASH % 28 28 30 30 45 45
FUEL FIRED t/h 110 272 129 319 174 430

ASH PRODUCED t/h 30.8 76.2 38.7 95.7 78.3 193.5

Pulverised Coal Combustion In
Tangentially Fired Boiler
Tangential Firing System
Arrangement
(Joseph. G. Singer, 1981 )
Tangential Firing System Corner
Windbox Arrangement
Flame In Tangential Firing
(Joseph. G. Singer, 1981 )
The Pattern of Recirculation In
Tangentially Fired Boiler.
(Joseph. G. Singer, 1981 )
 Design Features For Firing
Indian Coals
• The most important consideration for designing a coal
fired boiler is the fuel to be burnt.
• Such fuel / ash properties :
 The ash fusibility temperature - both absolute
values and differential between initial
deformation, Softening,
Hemispherical and fluid temperature.
 Slagging and fouling indices.
 Quantum of ash per million kilo calories heat
input.
COMBUSTION OPTIMISATION
 Combustion optimisation
• Optimisation of combustion in Indian high ash coal
fired boiler is of special interest due to the organic and
inorganic interaction and the large amount of variation
in the organic.
• The combustion behaviour of Indian coal in boiler
furnaces needs understanding of the complex organic
and inorganic mix up.
• The high percentage of ash, the low reactive in the
organic of coal, the encapsulation of organic in
inorganic, the oxidised coal in many cases and the
blending of many type of coals are some of the reasons
for varying behaviour of coals during combustion.
 Combustion optimisation (Cont)

• Indian high ash coals result in high

primary air requirements -primary
Combustion Dilution
• Sec. Air distribution at required
elevation is very important
• Avoid / reduce all unwanted sec. Air at
any location
• And divert them to other needy elevation.
 Combustion optimisation (Cont)

• Keep mill air flow just above settling velocity.

Do pitot traverse to check primary air flow.
Keep reducing primary air - settling start. Slight
furnace disturbance starts. Increase by primary
air 1-2 t/hr
• Keep total air flow - 20% excess air @ eco out
• Close all fuel air dampers if VM less than 20 -
22% Look flame front - decide for higher VM
coal
• Keep wind box pr. 100 - 150 mm - better
distribution Across elevation.
 Combustion optimisation (Cont)

• Wind Box Damper Setting for Completion of

Combustion and Bottom Ash Collection
• Increase LRSB Operation for Fouling Type
Ash in Coal And Exit Gas Temp. Control
• Change in SH Spray Pattern Due to Change in
Radiation Heat Transfer Because of Change
Combustion Completion Elevation.
• Check PC Analysis on Rieve Distribution.
Chart / Roslin-Rammler Chart
 Combustion optimisation (Cont)

Wall Blower Optimisation

• Change in SH spray without change
in other parameters indicates
furnace deposit increase
• SH spray increase above a particular
level (to be determined for each
boiler) operate wall blowers
 Combustion optimisation (Cont)

 Operate All 88 Blowers

See The Effect On SH Spray
Wall Blow Each Row - Study Effect
Watch SH Spray Drop & Regain Time
Interval Between Blowers
Interval Between Blowers To Be Constant
Repeat Each Row Independently
 Repeat 2 Adjacent Rows
 Repeat 2 Alternate Rows
 Repeat Blowers In Front & Rear And L & R
Separately And Study The Effect On SH Flow
 Combustion optimisation (Cont)

 Top Mill Combination Wall Blow Row 3 & 4 Once In 4 - 6

Hours Time Interval. Check With Field Data.
 Before A Planned Shut Down Do Not Wall Blow For 16 - 24
Hours And Take A Photo Of All Walls From Top Good For
Soot Blower Optimisation
 Check Need For 5th Row Addition
 Use LRSB To Reduce Exit Gas Temp. Normally Not A
Problem In Indian High Ash Coals.
 +50 Mesh Mainly Contributes For Bottom Ash %.
 +100% Also For Agglomerating Type Of Ash In Coal
 Removal Of Deposits, From Areas Of Higher Deposit, More
Frequently Keep Bottom Ash Quantity Low.
 Combustion optimisation
OTHER TIPS
• Check % VM in Coal by HCl Leaching Once in
a Month If VM > 20% and Flame Front Away
From Nozzle
• FC/VM Ratio Vs % FA Comb. Is Very Good
for 500 Mw Unit - Establish This for Your
Plant
• +50 Retention for Bottom Ash
 Combustion optimisation (Cont)

• For high reactive coal - if achieving SH

temp is a problem
– Keep AA &HH as bottom and top air &
keep lower wind Box pressure 50 - 75 mmwc
• If bottom ash % comb. Is increasing
– Check +50 mesh - keep around 1%
– Open AA to 50%
• Up to 10% BA comb. Is ok
 ANALYSIS AND INFERENCE
FROM FIELD DATA
• List All Parameters Influence The Dependent
Variable
• SaySH Spray Flow Coal Quality
% Excess Air
Wall Blowing
WB Damper
Wind Box Pr
OFA Operations
FW Inlet Temp
Sec Air Temp
APH Out FG Temp
ANALYSIS AND INFERENCE FROM
FIELD DATA Cont
BA Collection Coal Quality/Mines
Deposit Pattern
Excess Air
Primary / Sec Air Prop.
Wind Box Pr.
WB Damper Aux, FA,EA
% Ash In Coal
PC Coal Analysis
+50% Retention
 Measurements in Boiler for Combustion
Optimisation
• Air Flow
• Air Temperature
• Fuel Flow
• Fuel Distribution
• Flame Temperature Profile
• Flame Quality
• Gas Temperature at Furnace Outlet
• Gas Temperature at Boiler Outlet
• Flue Gas Products
• Pollutants in Flue Gas
 Fuel Distribution
• Fuel distribution from the pulveriser is
very important
• Depends upon the resistance of each fuel
pipe
• It is necessary to equalise this to the
condition that the flow is  5 %
• This is done by flow measurement in
each pipe and deciding to insert orifices
 OPTIMISATION OF BOILER EFFICIENCY

HHV ALL LOSSES EFFICIENCY

GAS OUT TEMP DRY,HYD.,FUEL MOIST,AIR EFFICIENCY

MOIST. SENSIBLE HEAT
LOSS
EXCESS AIR LOSSES DRY,AIR MOIST., EFFICIENCY
CARBON LOSS
FUEL MOISTURE LOSS EFFICIENCY

AIR MOISTURE LOSS EFFICIENCY

HYDROGEN IN FUEL H2 LOSS EFFICIENCY

UNBURNTS CARBON LOSS EFFICIENCY

MILL REJECTS RATE LOSS EFFICIENCY

MILL REJECT CV LOSS EFFICIENCY