PULVERIZER PLANT

• RAW COAL FEEDING SYSTEM

• BOWL MILL
• MILL REJECT SYSTEM

• MADE BY
• KISHORE KUMAR MARKAM
• DEEP CHAND RATHORE
• SHASHANK PRASAD
PULVERISED FORM OF COAL

• IT HAS MADE MODERN STEAM GENERATING UNITS HIGHLY

THERMAL EFFICIENT, RELIABLE AND SAFE.
• IT HAS MADE EFFICIENT USE OF LOW GRADE COALS.
• IT PROVIDES GOOD CONTROL OVER COAL AIR MIXTURE
PROPORTION, FLAME STABILITY WITH MINIMUM LEVEL OF
UNBURNT CARBON.
GRINDING PROCESS

RAW COAL FROM P.F. TO BOILER

COAL FEEDER

P.F.+AIR
HOT AIR GRINDING ZONE

REJECTS
RAW COAL FEEDING SYSTEM

• THE PURPOSE OF RAW COAL FEEDER IN THE COAL PULVERISING CIRCUIT OF A HIGH
PRESSURE BOILER IS TO FEED THE RAW COAL FROM THE BUNKER INTO THE PULVERIZER
IN CONTROLLED AND VARIED QUANTITIES CORRESPONDING TO THE BOILER LOAD
DEMAND.
• THE RAW COAL FEEDERS ARE GENERALLY PROVIDED WITH A VARIABLE SPEED DRIVE
WHICH ENABLE THE CONTROLLED VARIATION OF THE FEEDER SPEED.
• THE RAW COAL FEEDERS ARE BROADLY CLASSIFIED INTO
• VOLUMETRIC FEEDERS, GRAVIMETRIC FEEDERS
• IN VOLUMETRIC FEEDING THE QUANTITY OF COAL FEED TO THE PULVERIZER IS IN TERMS
OF VOLUME AND THE GRAVIMETRIC FEEDER FEEDS THE COAL BY WEIGHT.
GRAVIMETRIC FEEDER

• IN VOLUMETRIC FEEDERS THE QUANTITY OF COAL FEED INTO THE PULVERIZER IS IN TERMS
OF VOLUME AND NOT BY WEIGHT.
• DEPENDING UPON THE TYPE OF COAL MOISTURE CONTENT, SIZE DISTRIBUTION ,ETC. THE
BULK DENSITY OF RAW COAL IS BOUND TO VARY FROM TIME TO TIME .HENCE A CONSTANT
VOLUMETRIC FEEDING NEED NOT NECESSARILY BE A CONSTANT WEIGHT FEEDING.
• IN COAL FIRED HIGH PRESSURE BOILER THE EFFICIENCY DEPENDS ON THE AMOUNT OF
ACCESS AIR ALSO.
• BY MAINTAINING THE ACCESS AIR QUANTITY AT THE OPTIMUM LEVEL THE BOILER
EFFICIENCY CAN BE INCREASED .
• THE TWO IMPORTANT ASPECTS OF RAW COAL WITH DICTATES THE ACCESS AIR REQUIREMENT
FOR GOOD COMBUSTION ARE THE COAL ANALYSIS AND QUANTITY BY WEIGHT .
• OF THESE TWO THE COAL ANALYSIS IS BEYOND THE CONTROL OF A FEEDER WHERE AS THE
QUANTITY BY WEIGHT OF RAW COAL CAN BE CONTROLLED PROVIDED THE MODE OF FEEDING
IS GRAVIMETRIC.
PRINCIPLE OF OPERATION

• MASS FLOW RATE= BELT SPEED × MASS/UNIT LENGHT

• MASS FLOW EQUATION FOR GRAVIMETRIC FEEDER.
• THE MASS PER UNIT LENGTH IS KEPT CONSTANT AND BELT SPEED IS VERY
ACCORDING TO DEMAND SIGNAL THIS TYPE IS CALLED AS MECHANICAL
WEIGH TYPE OF GRAVIMETRIC FEEDER.
CLEAN OUT CONVEYER ASSEMBLY

• IN ORDER TO AVOID THE SPILLAGE OF COAL TO THE BOTTOM OF THE

FEEDER THE BED HAS GOT EXTRA WIDTH THAN THE INLET WIDTH AND ALSO
CURVES.
• IN SPITE OF ALL THESE ARRANGEMENTS A FEW PIECES OF COAL MAY SPILL
DOWN TO THE BOTTOM .
• IF THESE PIECES WERE ALLOWED TO REMAIN THERE THEY MAY CATCH FIRE
AFTER SOMETIME AND DAMAGE THE BELT.
• THE CLEAN OUT CONVEYOR SWEEPS ALL THE COAL FROM THE BOTTOM OF
THE FEEDER AND DELIVER IT TO OUTLET.
GENERAL SPECIFICATIONS 600MW FEEDER

• TYPE – BELT TYPE GRAVIMETRIC FEEDER

• CAPACITY – 20.4 TPH (MIN) / 102 TPH (MAX)
• GEAR RATIO – 128:1 MAIN DRIVE 1041:1 COC DRIVE
• BULK DENSITY OF COAL – 55 LBS/FT^3
• WORKING PRESSURE- 500 MMWC
• PURGE AIR REQUIRE- 12M^3/MIN/FEEDER
WHAT IS PULVERIZER?

• PULVERIZED COAL FIRING IS A METHOD WHERE BY THE CRUSHED COAL

GENERALLY REDUCED TO A FINENESS SUCH THAT 70- 80% PASSES THROUGH
A 200 MESH SIEVE CARRIED FORWARD BY AIR THROUGH PIPES DIRECTLY TO
THE BURNERS OR STORAGE BINS FROM WHERE IT IS PASSED TO BURNERS
AND DISCHARGE INTO COMBUSTION CHAMBER.
• THE MIXTURE OF COAL AND AIR IGNITES AND BURN IN SUSPENSION
CONDITION.
PULVERIZERS MAY BE DIVIDED INTO THREE
MAIN TYPES

Speed Low Medium High

10 to 20 RPM 40 to 70 RPM 900 to 1000
RPM
Type Ball tube mills Bowl Mill, Ball Impact or
and race mill Hammer Mill.

Beater Mill or
Fan Mill.
BOWL MILL

• XRP1103 WITH PLANETARY GEAR BOX

• X- 3 PHASE, 50HZ SUPPLY TO MOTOR
• R- RAYMOND
• P- PRESSURIZED
• 110- NOMINAL DIA OF BOWL ( INCHES)
• 3- NO. OF GRINDING ROLLERS
FIRING
DIRECT FIRING:
COAL IS GROUND AND IS DIRECTLY CARRIED FROM
THE PULVERISER TO THE FURNACE BY USE OF
PRESSURISED AIR. PRESSURISED AIR FROM PRIMARY
AIR FANS GOES TO THE PULVERISERS. SUFFICIENT
TEMPERATURE IS MAINTAINED FOR DRYING OF COAL
AND MOVING TO THE FURNACE WITHOUT SETTLING.
INDIRECT FIRING:
HERE COAL IS GROUND AND IS CARRIED TO AN
INTERMEDIATE BUNKER. BASED ON THE UNIT LOAD
DEMAND COAL MOVES FROM THE INTERMEDIATE
BUNKER TO THE FURNACE. A SUCTION FAN HELPS IN
SUCKING THE PULVERSISED FUEL TO THE FURNACE.
THIS SYSTEM IS SUITABLE, WHERE THE BOILER LOAD
VARIES AND THE MILLS CONSUME HUGE POWER. BUT,
THE DISADVANTAGE IS THAT, THE CAPITAL COST IS
HIGH DUE TO EXTRA BUNKERS AND FANS.
FUNCTIONAL REQUIREMENTS OF
PULVERISER

• GRINDING OF COAL
• DRYING OF COAL
• REJECTING UNDESIRABLE REJECTS LIKE PYRITES & STONES
• TRANSPORTATION OF PULVERISED COAL
BOWL MILL

Bowl mills are employed to pulverize the pre-crushed

raw coal to the required fineness before it is
admitted into the boiler furnace for combustion. The
operating characteristics of bowl mills make it the
best mill available for the direct firing system
of the coal. The best features of all the pulverisers
have been incorporated in the design of the bowl
mill.
MILL DETAILS 600 MW

• CAPACITY- 86.6 TPH

• SYSTEM- COLD PA / PRESSURISED
• TYPE OF LOAD- MODERATE SHOCK LOAD
• SPRING RATE – 5359 KG/CM
• SPRING PRE LOAD – 9500KG
• MILL O/L TEMP RANGE – 65-90°C
• AIR FLOW PER MALLI 136 TPH
• AIR TEMP AT MILL INLET- 249°C
• FINENESS THROUGH 200 MESH- 70%
• NO. OF MILL IN OPERATION- 6
PLANETARY GEAR
 PRIMARY AIR FLOW
Primary air provides the means to dry,
classify, and transport the coal from the
grinding zone of the mill through the
classifier & PF pipes to the furnace
Two constraints for the PA flow are:
• Ability to maintain the minimum air
velocity (15–16 m/sec) to transport the
coal.
SEAL AIR SYSTEM

Seal air for the journal assembly is supplied through

the ends of the trunnion shaft, through holes bored
through the shaft and into the journal head. The mill
area above the bowl is usually under suction, and air
is pulled into this area. The air flows from the journal
head through the small annular clearance between
the upper journal housing and the journal head skirt.
The journal housing rotates, and the journal skirt is
stationary. The flow of seal air prevents the coal dust
from going up to the area around the oil and possibly
contaminating the oil supply.
LUBRICATION
•Lubrication of Gearbox components
• Upper radial bearing by external Lubrication
system
• Sump lubrication of Lower radial bearing and
thrust bearing
• Worm gear and worm shaft bearings lubricated
by sump oil. The worm shaft bearings are
splash lubricated.
•Lubrication of Roller Journal assembly Bearings
• The journal assembly is filled with oil and
internal circulation takes place as the roller
assembly rotates around its axis.
LUBRICATION RUNNING PARAMETERS

Oil cooler Shell Tube

Pressure(kg/cm2) 15 9.5
Media Oil Water
Inlet temp °c 55 39
Outlet temp°c 45 42
Fluid Servo mesh SP720 Treated water
Flow LPM 250 175
MILL REJECION SYSTEM

• MILL HAS BEEN DESIGNED TO REJECT TRAMP IRON, PYRITES

& OTHER DENSER & DIFFICULT TO GRIND MATERIAL. WHEN
THESE COME UNDER THE ROLLER, THE ROLLER LIFTS UP
ALLOWING THESE TO PASS UNDER. THESE ARE FURTHER
CARRIED OVER THE EDGE OF THE BOWL & DROP THROUGH
THE MILL SIDE AIR INLET HOUSING. THEN, SCRAPPED BY
SCRAPPERS THROUGH TRAMP IRON SPOUT TO PYRITE
HOPPER, FROM WHERE THEY ARE PERIODICALLY REMOVED
 CLASSIFIER SETTING

• SETTING OF CLASSIFIER IS ADJUSTING THE OPENING OF THE CLASSIFIER.

• THERE ARE 2 POSITIONS AT THE EXTREME.
• 0 : MEANS ALL CLASSIFIER VANES ARE FULLY OPEN
• 10 : MEANS ALL CLASSIFIER VANES ARE CLOSED.
• BASED ON THE FINENESS ANALYSIS, THE CLASSIFIER IS SET TO ACHIEVE THE
DESIRED FINENESS LEVEL.
CLASSIFIER SETTING

For optimum mill operation, the classifier pointers

should be set between 0 and 3. If the coal is too
fine when the setting is on point 1, the spring
pressure on the rolls may be too great. If the coal
is too coarse when the setting is on 3, the spring
pressure on the rolls may not be enough.
OPERATING PARAMETERS
MILL AIR FLOW – MILL SHOULD BE OPERATED AT THE DESIGN
AIRFLOW AT ALL LOADS. OPERATING AT HIGHER
AIRFLOW WILL CAUSE EXCESS WEAR AND UPSET
THE PERFORMANCE OF CLASSIFIER ETC.

MILL OUTLET TEMPERATURE – TOO HIGH A OUTLET TEMPERATURE

MAY LEAD TO A PULVERISER FIRE & TOO LOW
OUTLET TEMPERATURE MAY NOT DRY THE COAL
SUFFICIENTLY.

PULVERISED FUEL FINENESS – LOW FINENESS RESULT IN UNBURNT

CARBON & HIGH FINENESS RESULT IN INCREASE IN
WEAR RATE & REDUCTION OF MILL CAPACITY.

MILL CAPACITY – THE CAPACITY OF MILL DEPENDS ON THE HARD

GROOVE GRINDABILITY INDEX, THE MOISTURE
CONTENT OF COAL & THE PULVERISED FUEL
FINENESS OUTPUT REQUIRED.
OPERATING PARAMETERS
• MAINTAIN Mill Outlet Temperature
BETWEEN 70-80°C.
• REDUCE THE MILL LOAD IF Mill Outlet
temperature DROPS BELOW 60°C
• MAINTAIN PF FINENESS between 65-75%
THRU 200 MESH AT A MILL LOAD OF
DESIGNED MILL CAPACITY
OPERATING PARAMETERS

• MAINTAIN BOWL DP ≤ 300 mm WC

• REDUCE THE SPRING COMPRESSION BY 5% FOR
EVERY 10 POINT INCREASE IN HGI
• MAINTAIN VARIBLE AIR FLOW TO IMPROVE
COMBUSTION, REDUCE WEAR AND MAINTAIN P.F.
FINENESS
MILL FIRE
The usual causes of pulveriser fires are:
i) Excessive Mill Outlet temperatures
ii) Foreign material such as paper,
bags, belt etc.
iii) Excessive accumulation of pyrites
or coal at the mill bottom or air
inlet to the mill.
iv) Improper or unusual operation
THANK YOU