Bharat Heavy Electricals Limited TIRUCHIRAPALLI

Case study:

Project Bakreswar TPP, West Bengal (WBPDCL), unit # 4 (210MW)

Synchronized on 23 Dec 2007

Designed for Firing 100% Indian Coal.
Problem Reported On 20-11-2008 unit was shutdown as right hand side ring header
was observed in red hot condition. After shutdown it was
observed that the ash was filled up to bottom of burner panel (17
m) and the furnace bottom hopper also filled with ash.
Probable Reason 1. Improper de-ashing of bottom ash hopper..
2. Improper coal fineness

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 COAL ANALYSIS
Proximate analysis

Parameter Unit Coal (test) Design coal Worst coal

Moisture % by weight 5.8 8 15
Volatile matter % by weight 20.3 20 15
Ash % by weight 43.6 40 45
Fixed carbon % by weight 30.3 32 25
Calorific value % by weight 3640 3900 3200

Ultimate analysis
Parameter Unit Coal (test) Design coal Worst
coal
Carbon % by weight 38.0 42 34.6
Hydrogen % by weight 2.2 3 2.3
Nitrogen % by weight 1.2 0.9 0.3
Sulphur % by weight 0.4 0.3 0.6
 ASH ANALYSIS

Chemical composition Ash fusion temperature

0
(Oxidising atmosphere C)
Parameters % by weight
Initial defor-mation temp 1290
Silica SiO2 54.8
Aluminium oxide (Al2O3) 26.3 Softening temp >1450
Hemispherical temp >1450
Iron oxide (Fe2O3) 7.2
Fusion temp >1450
Titanium oxide (TiO2) 1.1

Calcium oxide (CaO) 3.3

Magnesium oxide (MgO) 1.0

Sodium oxide (Na2O) 0.8

Potassium oxide (K2O) 1.8

Sulphate (SO3) 2.9

 ASH ANALYSIS

Parameters Unit Clinker 1

Deformation Temp. Deg. C 1323
Sphere Temp. Deg. C 1362
Hemisphere Temp. Deg. C > 1450
Flow Temp. Deg. C > 1450
Density g/cc 1.28
 Parameters Unit Clinker 2
Deformation Temp. Deg. C 1254
Sphere Temp. Deg. C 1284
Hemisphere Temp. Deg. C 1369
Flow Temp. Deg. C > 1450
Density g/cc 2.3
 Parameters Unit Clinker 3
Deformation Temp. Deg. C 1259
Sphere Temp. Deg. C 1283
Hemisphere Temp. Deg. C 1385
Flow Temp. Deg. C > 1450
Density g/cc 2.2
 Parameters Unit Clinker 4
Deformation Temp. Deg. C 1289
Sphere Temp. Deg. C 1314
Hemisphere Temp. Deg. C 1384
Flow Temp. Deg. C > 1450
Density g/cc 1.7
 Parameters Unit Clinker 5
Deformation Temp. Deg. C 1264
Sphere Temp. Deg. C 1283
Hemisphere Temp. Deg. C 1360
Flow Temp. Deg. C >1450
Density g/cc 3.3
Bharat Heavy Electricals Limited TIRUCHIRAPALLI

Chemical composition of Clinker samples

Parameters Unit Clinker Clinker Clinker Clinker Clinker
No. 1 No. 2 No. 3 No. 4 No. 5
Silica ( SiO2) % by wt 55.8 58.2 57.0 58.2 59.7
Aluminium Oxide ( Al2O3) % by wt 27.6 25.4 27.1 25.4 24.1
Iron Oxide ( Fe2O3) % by wt 7.4 6.8 7.4 7.4 6.6
Titanium Oxide ( TiO2) % by wt 1.2 1.3 1.1 1.4 1.2
Calcium Oxide ( CaO ) % by wt 3.5 3.4 3.2 3.0 3.3
Magnesium Oxide (MgO ) % by wt 0.8 0.7 0.6 0.7 0.9
Sodium Oxide (Na2O) % by wt 0.3 0.3 0.4 0.4 0.3
Potassium Oxide ( K2O ) % by wt 1.9 2.4 2.1 2.4 2.6
Sulphate ( SO3 ) % by wt 1.3 1.2 0.9 0.9 1.1

OTHER PARAMETERS
Parameters Unit Clinker Clinker Clinker Clinker Clinker
No. 1 No. 2 No. 3 No. 4 No. 5
% by wt
Loss on ignition 0.4 --- 0.5 --- ---
% by wt
Gain on ignition --- 0.3 --- 0.4 0.8
g / cc
Density 1.28 2.3 2.2 1.7 3.3

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CLINKER SAMPLES
Hard ash at S panel area
SHEARING OF I CHANNEL FROM BUCKSTAY END RESTRAINT BRACKET FROM
RIGHT SIDE WW IN CAT HOUSE ( S PANEL AREA)
Bharat Heavy Electricals Limited TIRUCHIRAPALLI

Time taken for ash to build up in the

furnace
• The volume of furnace from S panel to Bottom of
burner is about 1200 M3 .
• Boiler running with 210 MW with 125 tons coal per
hour with 40 % ash will produce 5 tons of bottom
ash( 10 % total ash as bottom ash).
• With a bulk density of 1 T/ M3 of ash
• Ash collection time= 1200/(24X5X1) days=10 days
• The ash accumulation time could be shorter in
abnormal conditions

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Bharat Heavy Electricals Limited TIRUCHIRAPALLI

Observations after clinker formation

• The ash accumulation in the furnace was up to 17 m level. The

deposits were porous and easy to remove at the top and very
hard near the S panel.
• The Chemical composition of deposits are almost same
however there is a difference in the density of various
samples.
• The ash hopper below s panel was filled with fused ash
implying the build up started in the ash hopper.
• The pulverized coal fineness was poor in few mills.
• The furnace walls were generally clean

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Bharat Heavy Electricals Limited TIRUCHIRAPALLI

Coal Slagging potential

Description Unit Value Remark
BASE / ACID RATIO   0.17 low slaging

Sulphur Slaging index   0.07 low slaging

IRON/ CALCIUM RATIO   2.18 low slaging

FUSION SLAGGING INDEX   1322.00 low slaging

SILICA /ALUMINA RATIO   2.08 medium slaging

DOLAMITE PERCENTAGE (DP) % 30.50 low slaging

SODIUM OXIDE % by Wt 0.80 low slaging

TOTAL ALKALIES( NA2O+K2O) % by Wt 2.60 low slaging

IRON OXIDE % by Wt 7.20 low slaging

Committed to making a better world

Bharat Heavy Electricals Limited TIRUCHIRAPALLI

Reasons for furnace ash accumulation in

furnace bottom

• 1. Improper de-ashing of bottom ash hopper..

• 2. Improper coal fineness

Committed to making a better world

Bharat Heavy Electricals Limited TIRUCHIRAPALLI

Steps to be taken to avoid ash accumulation in

furnace bottom
• Run the unit with proper excess air.
• Maintain proper coal fineness
• Maintain design air flow through mills (not high).
• Have a periodic watch at furnace bottom.
• Bottom ash should be emptied in every shift. A report about
it should be recorded in control room. Any abnormality of
bottom ash should be investigated and corrective action to be
taken
• Wall blowers and soot blowers should be operated regularly.
If operation is after long gap vigil should be kept.

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THANK
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