Combustion Optimization

OFA CORNER –2 CORNER –3

OFA
FF AA

F FA

EF AA
SECONDARY AIR
E FA SECONDARY
AIR
DE AA

D FA
FRONT WATER WALL CORNER –4
CORNER –1
CD AA

C FA
OIL GUN HFO + LDO
BC AA

B FA PULVERIZED COAL + SA

AB AA
SCANNERS
A FA
OIL IGNITOR / HEA
AA AA
 LOSSES ENCOUNTERED IN BOILER
• CONTROLLABLE
– COMBUSTIBLE IN ASH LOSS
– DRY GAS LOSS
– CARBON MONOOXIDE IN FLUE GAS
• UN CONTROLLABLE
– MOISTURE IN FUEL
– HYDROGEN IN FUEL
– AIR MOISTURE
– SENSIBLE HEAT IN ASH
– RADIATION AND UNACCOUNTED
 AREAS CONTRIBUTING TO LOSSES IN A BOILER

• COMBUSTION IN BOILER
• AIRHEATER PERFORMANCE
• MILL PLANT PERFORMANCE
• FANS
• WATER LOSSES
 FACTORS AFFECTING COMBUSTION

• SURFACE CONTACT AREA OF FUEL WITH AIR

• AIR-FUEL RATIO
• RETENTION TIME
• COMBUSTION CHAMBER TEMPERATURE
• TURBULANCE IN COMBUSTION CHAMBER
• REMOVAL OF PRODUCTS OF COMBUSTION
 CARBON LOSS

• HEAT LOSS DUE TO UNBURNT CARBON LEAVING

THE BOILER ALONG WITH EITHER BOTTOM ASH
OR FLY ASH
 FACTORS AFFECTING CARBON LOSS

1 AIR DISTRIBUTION
– DISTRIBUTION
– EXCESS AIR
2 PARTICLE SIZE
– MILL FINENESS -200
– MILL FINENESS +50
3 COAL QUALITY
– VOLATILE MATTER
4 COMBUSTION
– TIME
– TEMPERATURE
– TURBULANCE
 FLUE GAS QUANTITY
• EXCESS AIR
– MORE THAN OPTIMUM
INCREASES DRY GAS LOSS
– LESS THAN OPTIMUM
INCREASES CARBON LOSS
– OPTIMUM EXCESS AIR IS
DETERMINED THROUGH
FIELD TESTS
– OPTIMUM EXCESS AIR
CAN BE MAINTAINED
THROUGH F.G. ANALYSIS
The Model for Combustion Control
Fans
Fan Characteristic
Fan Characteristic
Fan Characteristic
Fan Characteristic
Fan Characteristic
 Slagging in Furnace
• If furnace flue gas temperature at the furnace exit exceeds the
softening temperature of the ash, total heat absorption by the water
walls must be increased to lower furnace exit gas temperature.
• Furnace exit gas temperature is reduced through combustion
optimization. It allows combustion to be completed lower in the
furnace and-or increased cleanliness of the water-walls through
sootblowing.
• Combustion optimization that concentrates on proper air flow
proportions and distribution, fuel balance and fineness also
homogenizes furnace temperatures and O2 levels to reduce areas of
"peaking" temperatures that cause localized slag accumulations.
Slagging in Furnace
Draught Control
 Pressure Variation

Pressure Variation in Air & Gas Path at Full Load

3000
2500
2000
1500
Pressure (Pa)

1000
500
0
-500 1 2 3 4 5 6 7 8 9 10 11 12
-1000 Boiler APH ESP ID Fan
FD Fan Duct SCAPH Duct APH Duct Wind
-1500 Box
-2000
-2500
Path Element

Calculated (215 MW) Design (210 MW)

Draught Control
Milling System
 Flow Diagram In “E” Mills –Air Flow path

160 – 340 0 C

65 – 120 0 C

Ambient Primary
Air

Seal Air
Classifier