GVK Power Low VM Coal Firing 07 08 16.ppsx

GVK Power (Goindwal Sahib)Ltd.
Low Volatile Matter Coal Firing in
2x270 MW GVK Power (Goindwal Sahib) Ltd.,

Boilers
Low Volatile coal Combustion, S R Kannan, May 2016

GVK Power (Goindwal Sahib)Ltd.,
The common coals used are bituminous and sub-bituminous .
Calorific Value Range

Grade (Kcal/Kg)
A Exceeding 6200
B 5600 – 6200
C 4940 – 5600
D 4200 – 4940
E 3360 – 4200
F 2400 – 3360
G 1300 – 2400
The gradation of Indian coal is based on its calorific value.

D,E and F coal grades are available for Power Generation in India.

Proximate of Indian, Indonesian and South African Coal
Proximate analysis of :
Indian Indonesian South African
Coal Coal Coal
Moisture % 5.98 9.43 8.50
Ash % 38.63 13.99 17
Volatile matter % 20.70 29.79 23.28
Fixed Carbon % 34.69 46.79 51.22
Typical range of volatile matter in Indian coal is 20 to 35%.

Proximate Analysis of GVK 2x270 MW Coal - Earlier, Proposed & Design

Sl Design
Description Earlier Coal Proposed Coal
No Coal
1 Total Moisture % 7.16 to 9.78 4.5 11.5
2 Inherent Moisture % 2.6 to 7.29 1 to 2
3 Volatile Matter % 21.89 to 25.36 16 to 18% (ADB) 22.36
4 Fixed Carbon % 28.6 to 32.44 38 to 40 % (ADB) 36.7
5 Ash % 38.75 to 43.07 40 - 42% (ADB) 29.44
6 GCV Kcal/Kg 3804 to 3919 (ADB) 4200 to 4400 (ADB) 4522
7 GCV Kcal/Kg 3701 to 3735 (ARB) 4100 to4200 (ARB)
Presence of low Volatile Matter in the proposed Coal is the cause for concern
Volatile matters present in the coal are:
1. Methane,
2. Hydrocarbons,
3. Hydrogen,
4. Carbon monoxide, and
5. Incombustible gases like carbon dioxide &
nitrogen.

Coal Combustion Process:
1. Pyrolysis (Pulverized coal is injected from the burner into the boiler
furnace. The pulverized coal particles are heated by radiation and heat
transfer by convection, and the volatile matter is released.).
2. Homogenous combustion of volatiles, producing char
3. Heterogeneous combustion of solid char.
Char burns slowly which controls the overall combustion

rate.

Effect of low volatile matter on coal Combustion
• Heat released during the combustion of volatiles is insufficient to

raise the Char temperature to ignition level to sustain combustion.
• Fuel Ratio (Fixed Carbon/Volatile Matter - FC/VM) is commonly used

to evaluate the combustibility of coals.
• Coal with fuel ratio of 1.2 to 1.8 is considered for Boiler Furnace
sizing.

Influence of volatile matter in coal combustion:

1. Proportionately increases flame length, and helps in easier ignition
of coal.
2. Sets minimum limit on the furnace height and volume.
3. Influences secondary air requirement and distribution aspects.
4. Influences secondary oil support

3 T’s of Combustion
Good combustion is accomplished by controlling the “3 T’s”.
1. Temperature high enough to ignite and maintain ignition of the fuel
(VM),
2. Turbulence or intimate mixing of the fuel and oxygen (Sec Air
Velocity), and
3. Time sufficient for complete combustion – Furnace Residence Time.
Furnace Residence Time:
Furnace residence time – char travel from burner top to Platen SH
Bottom.
Residence time depends on fuel ignition characteristic and reactivity.
Fuel ratio (FC/VM) is the good indication of the fuel reactivity.
A minimum furnace residence time is necessary to ensure complete
combustion of Char particles.

IGNITABILITY INDEX
I.I. = [(raw coal calorific value kCal/kg) – 81 *(Fixed carbon%)]

_________________________________________________
(volatile matter %) + ( moisture %)
If the ignitability index is 35 or less, measures for ignitability

improvement should be taken.

Furnace
height

Material used in Boiler

Material ASME Specification Temp Limit Oxidation limit
Carbon Steel SA-210 A1/ C 427°C 454°C
1-1/4 Cr-1/2Mo SA-213 T-11 552°C 575°C
2-1/4 Cr-1 Mo SA-213 T-22 577°C 593°C
9 Cr-1 Mo-V SA-213 T91 635°C 649°C
18 Cr-8 Ni SA-213 TP304H 704°C 760°C
18 Cr-10 Ni-Cb SA-213 TP347H 704°C 760°C

Temperature&&Heat
Temperature HeatPick
PickUp
upininvarious
varioussections
sectionsofinthe
Boiler
Boiler
Eco Inlet Temp 247 0C
Heat Pick up in Eco 40 0C
Eco Outlet Temp 287 0C
In Waterwall 65 0C
Drum Temp 352 0C
In 2nd Pass Steam Cooled
Wall and LTSH > 51 0C
LTSH Outlet Temp > 403 0C

Platen Super Heater Inlet Temp 403 0C
In Platen Super Heater > 101 0C
Platen Super Heater Outlet Temp > 504 0C

FinalSuper Heater Inlet Temp 504 0C
In Final Superheater 36 0C
Final Super Heater Outlet Temp 540 0C

Reheater inlet Temp 345 0C
In Reheater 195 0C
Reheater Outlet Temp 540 0C

Flue gas temperature & Flue Gas Cooled across the Boiler
Flue Gas
Flue Gas Cooled
Temp.
Furnace Temp. 1400 0C
In Furnace 269 0C
Platen Super heater inlet 1171 0C
In Platen Super heater 153 0C

Re heater Front Inlet 1018 0C

Re heater Rear Inlet 863 0C In Reheater 259 0C

Finish Super heater Inlet 759 0C
In Final Superheater 114 0C
LTSH Inlet 645 0C
In LTSH 182 0C
Eco Inlet 463 0C
In Economiser 124 0C
APH Inlet 339 0C
In APH 206 0C
APH Outlet 133 0C

Heat Lost by
Steam Temperature Heat Pick Up Heat Pick up
Flue Gas
Eco Inlet 247 0C
In Econimiser 40 0C 124 0C
Eco Outlet 287 0C
In Furnace Waterwall 65 0C 269 0C
Drum 352 0C
In 2nd Pass Steam
> 51 0C 182 0C
Cooled Wall and LTSH
LTSH Outlet > 403 0C

Platen Super Heater Inlet 403 0C
In Platen Super Heater > 101 0C 153 0C
Platen Super Heater Outlet > 504 0C

FinalSuper Heater Inlet 504 0C
In Final Superheater 36 0C 114 0C
Final Super Heater Outlet 540 0C

Reheater inlet 345 C
0

In Reheater 195 0C 259 0C
Reheater Outlet 540 C
0


Points For Discussion
1. Pulverised coal fineness

2. Mill outlet Temperature
3. Fuel air dampers
4. Burner Tilt
5. Un-burnt carbon
6. Oil Support
7. DESH Spray
8. Furnace wall Soot Blowing
9. Burner combinations
10. Shift in Heat transfer
11. Material Temperature limit and oxidation Limit
12. World wide experience in burning different coal

Pulverised coal fineness :
• Coal fineness affects ignition, flame stability, char

burnout etc.
• Ignition stability with low volatile coals can be

enhanced by grinding the coal finer.
• Pulverized coal fineness may have to be increased.
• classifier may need adjustments

Mill outlet Temperature:
• For higher VM Coal, the mill Outlet temperature is

limited to 65 0C.
• For lower VM coal the mill outlet temperature can

go up to 90 0C to aid for better ignition.

Fuel air dampers:
• Fuel air damper is to physically push the flame

front away from the burner tip.
• For low VM coal, this damper may have to be

fully closed.

Burner Tilt:
• To accommodate the residence time for the

burning of Char, more furnace height may be
required
• Burner tilt may have to be used.

Un-burnt carbon:
• Char burning is slow.
• Complete combustion may not be possible with the

existing furnace height.
• un-burnt carbon in Fly ash and Bottom Ash may be

in the higher side.

Oil Support:
• Heat released during the combustion of volatiles is

insufficient to raise the temperature of the char to
ignition level and sustain combustion.
• It may be necessary to provide Oil support to

maintain combustion and flame stability.

DESH Spray:
• Due to slow burning of char,
• Super heater / Re-heater Temperature may be high
• DESH spray may have to be used.

Furnace wall Soot Blowing:
• Furnace sizing is for the design coal, with Volatile

matter of 22.36%.
• Since VM is low, heat release is insufficient and heat

absorption in the furnace may be low.
• To enhance the heat absorption in the furnace, Wall

blowers may have to be used regularly.

Burner combinations :
• Super Heater and Re-heater outlet temperature may be

higher.
• Combination of higher elevation burners may be not

be possible.
• Bottom burners may have to be used to enhance

steam generation.

Shift in Heat transfer:

By firing low VM coal, the heat transfer pattern may change.
• A portion Re-heater and Super heater which are now shaded for
convection heat transfer, may be subjected to radiant heat
transfer.
• Flue gas temperature pattern may change.
• Metal Temperature may go up.
• Gases reaching the Furnace exit may be hotter than l200°C.
Furnece Height

Material Temperature limit and oxidation Limit.
Material used in the Super Heaters:
• SA 210 Gr A1- (only in water Wall)

• SA 213 T11,
• SA 213 T22,
• SA213 T91.
• SA213 TP 347H
Metal temp limit and oxidation limit is restricted for each material.
Metal temperatures may have to be watched continuously.

Summary:
Decrease in boiler efficiency through:

• Decreased steam production,
• Fouling of super heater tubes,
• Increased carbon loss,

• Loss of superheater / Reheater temperature control,
• Increased risk of fires in the economiser hopper,
• Air heater and particulate control system,
• Higher than desired exit temperature of exhaust gases.
We still need to burn coal. Therefore, the very least we can do is to
burn it optimally. While this sounds so simple it is, in fact, rather
complex and requires a deep understanding of the combustion
processes.

Thanks
Thanks

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GVK Power (Goindwal Sahib)Ltd.

Low Volatile Matter Coal Firing in

2x270 MW GVK Power (Goindwal Sahib) Ltd.,

Low Volatile coal Combustion, S R Kannan, May 2016

Calorific Value Range

The gradation of Indian coal is based on its calorific value.

Low Volatile coal Combustion, S R Kannan, May 2016

Proximate of Indian, Indonesian and South African Coal

Typical range of volatile matter in Indian coal is 20 to 35%.

Low Volatile coal Combustion, S R Kannan, May 2016

Proximate Analysis of GVK 2x270 MW Coal - Earlier, Proposed & Design

2 Inherent Moisture % 2.6 to 7.29 1 to 2

3 Volatile Matter % 21.89 to 25.36 16 to 18% (ADB) 22.36

4 Fixed Carbon % 28.6 to 32.44 38 to 40 % (ADB) 36.7

5 Ash % 38.75 to 43.07 40 - 42% (ADB) 29.44

6 GCV Kcal/Kg 3804 to 3919 (ADB) 4200 to 4400 (ADB) 4522

7 GCV Kcal/Kg 3701 to 3735 (ARB) 4100 to4200 (ARB)

Volatile matters present in the coal are:

Low Volatile coal Combustion, S R Kannan, May 2016

Coal Combustion Process:

2. Homogenous combustion of volatiles, producing char

3. Heterogeneous combustion of solid char.

Char burns slowly which controls the overall combustion

Low Volatile coal Combustion, S R Kannan, May 2016

Effect of low volatile matter on coal Combustion

• Heat released during the combustion of volatiles is insufficient to

• Fuel Ratio (Fixed Carbon/Volatile Matter - FC/VM) is commonly used

Low Volatile coal Combustion, S R Kannan, May 2016

Influence of volatile matter in coal combustion:

Low Volatile coal Combustion, S R Kannan, May 2016

Low Volatile coal Combustion, S R Kannan, May 2016

I.I. = [(raw coal calorific value kCal/kg) – 81 *(Fixed carbon%)]

If the ignitability index is 35 or less, measures for ignitability

Low Volatile coal Combustion, S R Kannan, May 2016

Low Volatile coal Combustion, S R Kannan, May 2016

Material used in Boiler

Carbon Steel SA-210 A1/ C 427°C 454°C

1-1/4 Cr-1/2Mo SA-213 T-11 552°C 575°C

2-1/4 Cr-1 Mo SA-213 T-22 577°C 593°C

9 Cr-1 Mo-V SA-213 T91 635°C 649°C

18 Cr-8 Ni SA-213 TP304H 704°C 760°C

18 Cr-10 Ni-Cb SA-213 TP347H 704°C 760°C

Low Volatile coal Combustion, S R Kannan, May 2016

Low Volatile coal Combustion, S R Kannan, May 2016

In Platen Super heater 153 0C

Low Volatile coal Combustion, S R Kannan, May 2016

Low Volatile coal Combustion, S R Kannan, May 2016

Points For Discussion

1. Pulverised coal fineness

Low Volatile coal Combustion, S R Kannan, May 2016

Pulverised coal fineness :

• Coal fineness affects ignition, flame stability, char

• Ignition stability with low volatile coals can be

• Pulverized coal fineness may have to be increased.

• classifier may need adjustments

Low Volatile coal Combustion, S R Kannan, May 2016

Mill outlet Temperature:

• For higher VM Coal, the mill Outlet temperature is

• For lower VM coal the mill outlet temperature can

Low Volatile coal Combustion, S R Kannan, May 2016

Fuel air dampers:

• Fuel air damper is to physically push the flame

• For low VM coal, this damper may have to be

Low Volatile coal Combustion, S R Kannan, May 2016