Upload
rohit-meena
View
122
Download
3
Tags:
Embed Size (px)
Citation preview
BOILER & CO-GENERATION
HINDALCO INDUSTRIES LIMITED
MAJOR CONTITUENTS
DM PLANT COAL
HANDLIING PLANT
CO-GENERATION
PLANT
ASH ANDLING
PLANT
BOIILER
3
INTRODUCTION TO BOILER
ENCLOSED PRESSURE VESSEL
HEAT GENERATED BY COMBUSTION OF FUEL IS TRANSFERRED TO WATER TO BECOME STEAM
PROCESS: EVAPORATION
STEAM VOLUME INCREASES TO 1,600 TIMES FROM WATER AND PRODUCES TREMENDOUS FORCE
BOILER TO BE EXTREMELY DANGEROUS EQUIPMENT. CARE IS MUST TO AVOID EXPLOSION.
What is a boiler?
COGENERATION PLANT VIEW
20 A
TA
11 A
TA
3.9
ATA
11 A
TA
3.9A
TA
CONDENSER
CONDENSER
5 BAR TO PROCESS
M
~
20 A
TA
~~
~
H.P.HTR
35 MW
6 MW
31.4 MW
5.6 MW
54 ATA COMMON HEADER
43 A
TA H
EA
DE
R
54 ATA COMMON HEADER
To Economiser
From BFP
B#4 150 TPH
Reynolds
Digestion 1, 3 & 4
B#3 140 TPH
B#2 80 TPH
B#1 80 TPH
~
Auxiliary Steam
4 BAR STEAM
6 MW
600/
250
12 Bar steam to Dig-2
7 B
ar H
dr
7 BAR TO PROCESS
250 PSI from Hi-Tech
COGENERATIONPLANT•CO-GENERATION MEANS SIMULTANEOUSLY PRODUCTION OF POWER
& USEFUL THERMAL ENERGY FOR PROCESS FROM THE SAME PRIMARY ENERGY SOURCE. AS PER MINISTRY OF POWER CO- GENERATION IS DEFINED AS ONE WHICH SIMULTANEOUSLY PRODUCES TWO OR MORE FORMS OF USEFUL ENERGY SUCH AS ELECTRIC POWER AND STEAM, ELECTRIC POWER & SHAFT (MECHANICAL) POWER ETC... IT ALSO DEFINES ANY FACILITY THAT USES WASTE INDUSTRIAL HEAT FOR POWER GENERATION BY SUPPLEMENTING HEAT, NOT MORE THAN 50%, FROM ANY FOSSIL FUEL.• AT HINDALCO WE ARE HAVING THE COGENERATION PLANT IN WHICH WE USE THE STEAM FOR THE PROCESS REQUIREMENT AS WELL AS POWER GENERATION
WHAT IS A BOILER
ANY CLOSED VESSEL EXCEEDING 22.75 LITRES IN CAPACITY WHICH IS USED EXCLUSIVELY FOR GENERATING STEAM UNDER PRESSURE INCLUDES ANY MOUNTING AND OTHER FITTING ATTACHED TO SUCH VESSEL WHICH IS FULLY OR PARTIALLY UNDER PRESSURE WHEN SHUTOFF
AUXILIARIES OF BOILER
FANSINDUCED
DRAFT FAN
PRIMARY AIR FAN
FORCED DRAUGHT
FAN
ID FAN
•THE FUNCTION OF THIS FAN IS TO MAINTAIN THE DRAFT IN THE FURNACE AND CARAY OUT FLUE GAS OF THE FURNACE AND MAINTAIN THE NEGATIVE VALUE OF PRESSURE INSIDE THE FURNACE
PA FAN
•THE FUNCTION OF THIS FAN IS TO HEAT AND CARRY COAL FROM MILL TO THE FURNACE ( PULVERISHED COAL).
FD FAN
•THE FAN IS USED FOR THE PURPOSE OF SUPPLYING EXCESS AIR IN THE FURNACE FOR COMPLETE COMBUSTION OF COAL
AUXILIARIES OF BOILER• The function of air preheater is to heat the incoming air from
the Primary air fan which is supplied to the mills, Basically we are using this air as the medium for heating and conveying the Pulverized coal. The air preheater is located in the second pass of the Boiler and it gains its heat by the flue gases and gives the heat to the incoming air. AIR
PREHEATER
• The Economizer is the located in the second pass of the Boiler its function is to utilize the heat of flue gases coming out of the first pass of the Boiler which have done their work of producing steam from the Boiler. The economizer utilizes this heat of Flue gases which would otherwise be wasted to the atmosphere resulting in dry flue gas loss and reducing the efficiency of the Boiler.
ECONOMISER
AUXILIARIES OF BOILER • The function of the mill is to grind the coal in
the required size, like the size of coal required in the Pulverized fuel fired Boilers is of 75 microns so to achieve that size the mills are used. The mills used in the cogeneration plant are of Ball mill and Bowl mill type.
MILL
• The function of super heater is to superheat the Dry saturated steam coming from the drum and convert it into the superheated from so that chances of moisture is totally eliminated and the Enthalpy of steam is increased.
SUPERHEATERS
AUXILIARIES OF BOILER
• The function of the Electrostatic Precipitator is to collect the ash coming out of the Boiler and send it to the ash silo from where it is further utilized as per requirement. The ESP works on the principle of Corona where the Ash particles are charged by Direct Current and further collected at the collecting electrodes and than removed with the help of rappers and collected in the ash silos.ESP
12
DETAILS OF BOILERS
BOILERS TYPE CAPACITY PR.
KG/CM2TEMP.
0 C
YEAR OF COMMISSI
ONINGMAKE
BOILER # 1 FRONT FIRING
(PF)80 (TPH) 52.5 450 1986 WIL PUNE
BOILER # 2 AFBC 80 (TPH) 52.5 450 1989BHEL, TRICHI
BOILER # 3TANGENTIAL FIRING (PF)
140 (TPH) 111 535 1996BHEL, TRICHI
BOILER # 4TANGENTIAL FIRING (PF)
150 (TPH) 111 535 2004BHEL, TRICHI
STEAM GENERATION PER HOUR = 450 MT
STEAM RECEIVED FROM HI-TECH = 25-35 MT / HR
13
DM water
Deaerator
BFP
Coal to feeders by Dozer
Coal Conveyors
Rotory Coal Feeders
Furnace
Coal Transporting Line
Steam Generation
Flue Gas to ESP
PA Fan
FD Fan
Economiser
Water Circuit
Coal Yard
Coal sizing circuit for
-6mm size coalCoal
Bunkers
ID Fan
Ash Recycling feeder-2
No.
Steam to Power Plant / Process
Exchange of Heat Energy
Feeder Running
YES
AshHopper
NOAsh drai
n
Ash Recycling feeder-2
No.
Process Flow of Boiler#2
FLUIDISED BED COMBUSTION BOILER
15
AFBC BOILER
•AFBC – ATMOSPHERIC FLUIDIZED BED COMBUSTION
•DEFINITIONWHEN AIR OR GAS IS PASSED THROUGH AN INERT BED OF SOLID PARTICLE SUCH AS SAND OR CRUSHED REFRACTORY, THE AIR STARTS BUBBLING THROUGH THE BED AND PARTICLE ATTAIN A STATE OF HIGH TURBULENCE.UNDER SUCH CONDITIONS, THE BED
ASSUMES THE APPEARANCE OF A FLUID AND EXHIBITS THE PROPERTIES ASSOCIATED WITH A FLUID AND HENCE THE NAME AFBC
16
FBC MECHANISM
IF THE BED MATERIAL IN FLUIDIZED STATE IS HEATED TO THE IGNITION TEMPERATURE OF THE FUEL AND
THE FUEL IS INJECTED CONTINUOUSLY INTO THE BED, THE FUEL WILL BURN
RAPIDLY AND BED ATTAINS A UNIFORM TEMPERATURE DUE TO
EFFECTIVE MIXING.
17
AFBC BOILER - ADVANTAGE
• FLEXIBLE IN THEIR ABILITY TO BURN A WIDE RANGE OF FUEL.
• DOES NOT REQUIRE OIL SUPPORT FOR START UP OR LOW LOAD
STABILIZATION.
• BY ADDING OF LIMESTONE IN THE BED STRINGENT SOX EMISSION
CONTROL IS POSSIBLE WITHOUT EXPENSING DOWN STREAM
SCRUBBER EQUIPMENT
• AUXILIARY POWER CONSUMPTION IS LOW.
• BETTER LOAD RESPONSE AND CAN BE VARIED FROM 20% TO 100% OF
NCR.
• LESS INITIAL COST.
• EASY IN OPERATION.
• C & I REQUIREMENT FOR FBC ARE MINIMAL. NO BMS REQUIRED
18
AFBC BOILER - DISADVANTAGE
• SUITABLE FOR LOW AND MEDIUM CAPACITY ONLY.
• MORE MAINTENANCE COST DUE TO HIGH
EROSION OF TUBES.
• LOWER EFFICIENCY.
• MORE EFFORTS REQUIRED WHEN IT IS INITIALLY
START UP WITH CHARCOAL.
19
FUEL FEEDING SYSTEM
•Fuel is evenly distributed by judicious location of feed points for
burning most of the volatiles and carbon within the bed and to
avoid localized fuel concentration
Comp-1Comp-2Comp-3Comp-4
Coal feed points
Recycle ash feed points
Distributor plates
20
AIR DISTRIBUTION
•PROPER AIR DISTRIBUTOR IS REQUIRED TO ENSURE UNIFORM
DISTRIBUTION OF AIR ACROSS BED CROSS SECTION
Comp-1Comp-2Comp-3Comp-4
Nozzles are provided across the bed for proper air distribution
21
BED TEMPERATURE & HEIGHT
•BED TEMPERATURE: - FBC NORMALLY
OPERATES AT A TEMPERATURE RANGE
750-950º C FOR COAL
• BED HEIGHT: - DETERMINED BY THE NEED TO
SUBMERGE HEAT EXCHANGER TUBES AND IN CASE OF
HIGH SULPHUR COAL THE VOLUME REQUIREMENT FOR
EFFECTIVE SULPHUR CAPTURE
FOR MOST OF THE INDIAN FUELS A SHALLOW BED
LESS THAN 1000 MM IS ADEQUATE.
22
BED TEMPERATURE & HEIGHT
Water Head
er
Air from FD Fan
Coal Transporting Line
Primary Air
Bed material in Fluidization state
24
BLOCK DIAGRAM OF AFBC BOILER
NRV
PA FAN
ID Fans
FD FAN
BFP
DEAERATOR
FEED PUMP
PSH
ECO
APH
ESP
BFP (N)
BFP (S)
Final Steam to Process
DSHP
DSHP
To Common Header
FD FAN
FD FAN
PA FAN
PA FAN
SSH
134 2
25
TECHNICAL DATA
SN PARAMETER UNIT CAPACITY
1 Heating Surface M² 3426.9
2 Steam Flow TPH 80
3 Steam Pressure Kg/Cm²
52.5
4 Steam Temperature Deg C 450±5
5 Feed Water Temp. Deg C 105
6 Fluidized Air Temp Deg C 130
7 Boiler Efficiency % 82±1.5
Coal Size: -(-) 6 mm to Furnace with maximum 20% fines
26
Boiler Flue gas
Steam Output
Efficiency = 100 – (1+2+3+4+5+6+7+8)
(by In Direct Method)
Air
Fuel Input, 100%
1. Dry Flue gas loss2. H2 loss3. Moisture in fuel4. Moisture in air5. CO loss
7. Fly ash loss
6. Surface loss
8. Bottom ash loss
WHAT ARE THE LOSSES THAT OCCUR IN A BOILER?
27
INTERMITTENT BLOWDOWN
• THE INTERMITTENT BLOWN DOWN IS GIVEN BY MANUALLY OPERATING A VALVE FITTED TO DISCHARGE PIPE AT THE LOWEST POINT OF BOILER SHELL TO REDUCE PARAMETERS (TDS OR CONDUCTIVITY, PH, SILICA ETC) WITHIN PRESCRIBED LIMITS SO THAT STEAM QUALITY IS NOT LIKELY TO BE AFFECTED
• TDS LEVEL KEEPS VARYING• FLUCTUATIONS OF THE WATER LEVEL IN
THE BOILER.• SUBSTANTIAL AMOUNT OF HEAT ENERGY IS
LOST WITH INTERMITTENT BLOW DOWN.
28
•WHEN WATER EVAPORATES
•DISSOLVED SOLIDS GETS CONCENTRATED
•SOLIDS PRECIPITATES
•COATING OF TUBES
•REDUCES THE HEAT TRANSFER RATE
Why Boiler Blow Down ?
PULVERIZED FIRE BOILER SKETCH
30
PULVERIZED FUEL BOILER
Tangential firing
Coal is pulverised to a fine powder, so that less than 2% is +300 microns, and 70-75% is below 75 microns.Coal is blown with part of the combustion air into the boiler plant through a series of burner nozzles.
• Combustion takes place at temperatures from 1300-1700°C
• Particle residence time in the boiler is typically 2-5 seconds
• One of the most popular system for firing pulverized coal is the tangential firing using four burners corner to corner to create a fire ball at the center of the furnace.
31
ADVANTAGES ITS ABILITY TO BURN ALL RANKS OF COAL FROM
ANTHRACITIC TO LIGNITE, AND IT PERMITS COMBINATION FIRING (I.E., CAN USE COAL, OIL AND GAS IN SAME BURNER). BECAUSE OF THESE ADVANTAGES, THERE IS WIDESPREAD USE OF PULVERIZED COAL FURNACES.
DISADVANTAGES HIGH POWER DEMAND FOR PULVERIZING REQUIRES MORE MAINTENANCE, FLY ASH EROSION
AND POLLUTION COMPLICATE UNIT OPERATION.
Pulverized Fuel Boiler
32
PULVERIZEDFUELFIRING
33
FUELS SYSTEM IN PF BOILER#1
BALL MILL:-• IT IS FRONT WALL FIRED PULVERIZED FUEL BOILER
HAVING FOUR BURNERS ON FRONT WALL.
• BOILER NO. 1 IS PULVERIZED FUEL BOILERS.
• OIL GUNS IS PROVIDED FOR START UP AND SUPPORT AT
TWO LEVELS.
• MINUS 20 MM SIZE COAL IS FED TO THE MILL THROUGH
THE TWO NUMBER VOLUMETRIC COAL FEEDERS.
AS THE MILL ROTATES, THE COAL IN THE MILL IS PULVERISED
BY THE CRUSHING AND GRINDING ACTION OF CASCADING
STEEL BALLS. PREHEATED AIR WHICH COMES FROM PRIMARY
AIR FAN, AND FUEL MIXTURE, AFTER PASSING THROUGH THE
CLASSIFIERS, ENTERS THE COAL CONDUITS AND PASSES ON
TO THE BURNERS. THE OUTPUT OF THE MILL SYSTEM FOR A
GIVEN FUEL DEPENDS ONLY UPON THE AIR FLOW THROUGH
THE PULVERISER. A CONSTANT SPEED MOTOR THROUGH A
GEAR REDUCTION SYSTEM DRIVES THE MILL.
34
BALL MILL OF PF BOILER#1
35
FUELS SYSTEM IN PF BOILER#3 & 4
BOILER NO. 3 & 4 IS TANGENTIAL FIRED PULVERIZED FUEL BOILER HAVING FOUR ELEVATION BURNERS.
IN EACH ELEVATION FOUR COAL BURNER ARE AVAILABLE.
FOUR NUMBER BOWL MILLS ARE THERE TO CRUSH THE 20 MM SIZE COAL. OUT OF THESE FOUR MILLS, THREE MILLS SHOULD BE IN SERVICE FOR FULL STEAM LOAD.
BOWL AND ROLLERS ARRANGEMENTS ARE THERE TO CRUSH THE 20-MM SIZE COAL INSIDE THE MILL. HOT AIR FROM AIR PREHEATERS SUCKED BY THE EXHAUSTER OF RUNNING BOWL MILL CARRIES PULVERIZED COAL ON TO THE BURNERS AFTER PASSING THROUGH THE CLASSIFIERS.
36
QUALITY OF COAL
Coal Feed SizeBOILER #1, 3 & 4: 100% (-) 20 MM TO MILL
70% (-) 200 MESH TO FURNACE
BOILER#2 : (-) 6 MM WITH 20% FINES TO FURNACE
MOISTUREVOLATILEMATTER ASH
FIXEDCARBON
CALORIFICVALUE
10%-16% 21%-26% 35%-38% 25%-30%2900-3500
KCAL/KG
Proximate Analysis Values
37
. REDUCE STACK TEMPERATURE22O C REDUCTION IN FLUE GAS TEMPERATURE INCREASES BOILER EFFICIENCY BY 1%
. COMBUSTION AIR PREHEATING
. FEED WATER PREHEATING USING ECONOMIZER6OC RAISE IN FEED WATER TEMPERATURE, BY ECONOMISER/CONDENSATE RECOVERY, CORRESPONDS TO A 1% SAVING IN FUEL CONSUMPTION
IN ORDER TO IMPROVE THERMAL EFFICIENCY BY 1%, THE COMBUSTION AIR TEMP. MUST BE RAISED BY 20 DEG C.
ENERGY CONSERVATION OPPORTUNITIES IN BOILER
. INCOMPLETE COMBUSTION
38
Energy Conservation Opportunities in Boiler
. CONTROL EXCESS AIRFor every 1% reduction in excess air ,0.6% rise in efficiency.
. RADIATION AND CONVECTION HEAT LOSS. AUTOMATIC BLOWDOWN CONTROL. REDUCTION OF SCALING AND SOOT LOSSES. REDUCTION OF BOILER STEAM PRESSURE
Performance of a Boiler
hg -the enthalpy of saturated steam in kcal/kg of steam
hf -the enthalpy of feed water in kcal/kg of water
Boiler Efficiency: Direct Method
Boiler efficiency () = Heat output
Heat inputx 100 Q sx (hg – hf)
Q x GCVx 100=
PARAMETERS TO BE MONITORED: - QUANTITY OF STEAM GENERATED PER HOUR (QS) IN KG/HR - QUANTITY OF FUEL USED PER HOUR (Q) IN KG/HR- THE WORKING PRESSURE (IN KG/CM2(G)) AND SUPERHEAT
TEMPERATURE (OC), IF ANY - THE TEMPERATURE OF FEED WATER (OC) - TYPE OF FUEL AND GROSS CALORIFIC VALUE OF THE FUEL
(GCV) IN KCAL/KG OF FUEL
DM PLANT
THE WATER TO BE FEED IN BOILER FOR STEAM GENERATION MUST BE DEMINERALISED AS PER SHOULD NOT CONTAIN ANY DISSOLVED SOLID SUCH AS SILICA OR CHLORIDES AND CARBONATES WHICH RESULTS IN SLUDEFE FORMATION AND SCALE FORMATION IN THE BOILER RESULTING IN LOW EFFICIENCY OF BOILER ,LOW RATE OF STEAM GENERATION AND WASTAGE AND MORE CONSUMPTION OF FUEL ACCOMPANING WITH CORROSION OF INER BODY SURFACE OR CAN SAY METAL OF BOILER BODY .
SO FOR THIS PURPOSE WATER HAS TO BE TREATED FIRST AND SHOULD MAINTAIN TDS(TOTAL DISSOLVED SAOLID)AS LOW AS POSSIBLE BY PROPER TREATMENT .
DM PLANT PUMP PUMP AIR BLOWER PUMP FLOW CHART OF D. M. PLANT
CW TANK
DYNA- -SAND FILTER
M G F
A C F
S A C DEGASSED
WATER TANK
S B A
COLD DM TANK
F W TANK
DEMINERALIZATION OF WATER
• THE PROCESS OF DEMINERALIZATION RESULTS IN REMOVAL OF MINERALS FROM WATER,. CLEAR WATER IS RECEIVED FROM CLEAR WATER TANK AND THE MONITORING OF PH (9.7-10.2) AND CONDUCTIVITY (BELOW 150 MICRO SIEMENS/CM) ON DAILY BASIS IS MADE.
DYNA SAND FILTER
• SINGLE FILTER OF SAND SIZE 0.9 MM .ITS BASIC FUNCTION IS TURBIDITY REMOVAL, INLET TURBIDITY TO THE FILTER IS 200PPM AND OUTLET TURBIDITY IS LESS THAN 5 PPM ,ALUM DOSING IS ALSO DONE IN THIS FILTER.
MULTI GRATE FILTER
•THIS IS USED FOR THE REMOVAL OF TURBIDITY THE INLET TURBIDITY IS 40 PPM AND OUTLET TURBIDITY LESS THAN 5 PPM AT PRESENT WE ARE GETTING (0-1) NTU.
ACTIVATED CARBON FILTER•THIS IS USED TO ABSORB EXCESS CHLORINE, REMOVAL OF
ORGANIC MATTER AND OIL & GREASE IF ANY. AND CHARCOAL IS USED AS ACTIVATED CARBON IN THE ACTIVATED CARBON FILTER.
STRONG ACID CATION
•THE STRONG ACID CATION RESIN EXCHANGES ALL CATION IN WATER, THE CATION ASSOCIATED WITH ALKALINITY OR THOSE COMBINED AS NEUTRAL SALTS ALL ARE REMOVED BY SAC RESIN. I T HAS A GREATER AFFINITY FOR DIVALENT ION THAN THE MONOVALENT ION AS A RESULT SELECTIVITY OF CA AND MG IS MORE THAN FOR NA CONSEQUENTLY THE FRONT PORTIONS OF THE RESIN BED ARE PREDOMINANT WITH CA & MG, WHILE NA GOES TO THE TAIL SECTION OF THE RESIN BED AND SO THE NA ION SLIP OUT OF CATION EXCHANGER DUE TO REGENERATIVE EFFECT OF FREE MINERAL ACID
DEGASSER
•IT IS USED FOR CARBON DIOXIDE REMOVAL . CARBONIC ACID GENERATED IN SAC UNIT IS DECOMPOSED IN WATER+ CARBON DIOXIDE AND IT ESCAPES OUT FROM THE TOP OF DEGASSER BY DEGASSER BLOWER , MAXIMUM 6 PPM OF CO2 IS ALLOWED AFTER DEGASSER UNIT.
STRONG BASE ANION•SBA RESIN HAS GREATER AFFINITY FOR
IONIC SPECIES, SULFATE AND CHLORIDE THAN FOR THE MOLECULAR CARBON DIOXIDE AND SILICA AND HIGHER SELECTIVITY FOR SULFATE ION THAN CHLORIDE ION. AGAIN THERE IS DISTRIBUTION OF CONTAMINANTS OVER THE RESIN BED WITH FRONT LAYER HIGH IN SULFATE FOLLOWED BY CHLORIDE AND CARBON DIOXIDE AND THE SILICA AT TAIL END OF THE BED.
MIXED BED
•THE MIXED BED DEMINERALIZATION PROCESS CONSISTS OF SAC AND SBA RESIN INTIMATELY MIXED TO BRING ABOUT THE DEMINERALIZATION OF WATER, IN EFFECT IT IS MULTIPLE AND RANDOM TWO BED DEMINERALIZATION PAIRS RESULTING IN VERY HIGH QUALITY OF DM WATER . HERE THE LEAKAGE OF IONS CAUSED BY THE REGENERATING EFFECT OF FMA OR OF NAOH FORMED IN THE EXCHANGING PROCESS IS ABSENT ,THIS IS BECAUSE FMA GENERATED BY SAC RESIN IS EXCHANGED BY NEIGHBORING SBA RESIN LIKE WISE NAOH GENERATED BY SBA RESIN IS EXCHANGED BY ADJACENT SAC RESIN .CATION RESIN IS HEAVIER THAN THE SBA RESIN SO CATION FORMS THE DOWN LAYER . THE PARAMETERS AT THE OUTPUT ARE PH-6 TO7,CONDUCTIVITY 2 MICRO SIEMENS/CM, SILICA 0.02MG/LTR.
COAL HANDLING PLANT
coal yard
_20mm__2o_2o
BOILER # 1 & 2 BUNKER FLOORBunker
Boiler # 1 Bunker
Boiler # 2
BunkerBoiler # 3
Tripper
Tripper Conveyor
BOILER # 3 BUNKER FLOOR
TripperTrolley
Tripper Conveyor
Conveyor No. 64
Reciprocating Feeder 1or 2
Reclain Conveyor BC - 11831
To Old Circuit #1,#3 To Old Circuit # 2
Vibro Feeder Vibro Feeder
Impactor '+ / -' 6 mm'
Vibrating Screen
Impactor
-20mm Vibro Feeder
Vibrating Screen
'- 6 mm'Coal
'+6 mm' Coal
'+20 mm' Coal
'Buc
ket
Ele
vato
r
Daybin ConveyorBC - 33830
Conveyor - 70
Conveyor - 69
Conveyor - 65
Cross Conveyor
NEW COAL CIRCUIT - FLOW CHART (COAL PLANT)
Triveni / P.K.Sharma/ Sheet 1
'- 20 mm' Coal
COAL PLANT OPERATION
•COAL IS UNLOADING FROM WAGON TIPPLER IN TWO SIZES I E: - 01. +25 MM AND –75 MM (ABOVE 25MM AND BELOW 75 MM) 02. –25 MM AND + 75MM (BELOW 25MM AND ABOVE 75MM)
• AFTER UNLOADING OF COAL WE FED THE DIFFERENT SIZE COAL IN DIFFERENT BOILERS. WE HAVE FOUR BOILERS. THREE ARE PF AND ONE IS FBC. IN PF BOILER WE HAVE USE THE COAL BELOW THE 20MM. IN FBC BOILER WE HAVE USE THE COAL BELOW THE 6MM.FOR, WHICH VARIOUS EQUIPMENTS HAVE BEEN INSTALLED IN COAL PLANT AREA.•TO FEED THE COAL IN PF BOILERS (B#1,3 &4) PUSH THE COAL BY DOZERS IN ROTORY FEEDERS GRIZZLY SITUATED IN COAL YARDS. COAL IS COMING FROM RECLAIM CONVEYER TO CONVEYER#64, THEN VIBRATING SCREEN HAVING SIZE OF 20MM THROUGH VIBRO FEEDER. LESS THAT 20 MM COAL HAVE FALLEN THROUGH SCREEN DIRECTLY TO CONVEYER#70 AND OVERSIZE COAL GOING TO CONVEYER#70 THROUGH COAL IMPACTOR HAVING CAPACITY 120 TPH. FINALLY COAL IS GOING TO THE BUNKERS OF BOILER#1,3&4 THROUGH COMVEYER#70, DAYBIN CONVEYER AND TRIPPER CONVEYER.
•TO FEED THE COAL IN FBC BOILER (B#2) PUSH THE COAL BY DOZERS IN ROTARY FEEDERS GRIZZLY SITUATED IN COAL YARDS. COAL IS COMING FROM RECLAIM CONVEYER TO CONVEYER#64, VIBRO FEEDER THEN COAL IMPACTOR (240TPH) TO TWO NUMBERS VIBRATING SCREENS HAVING CAPACITY OF 120 TPH EACH THROUGH TWO VIBRO FEEDERS. COAL HAS FALLEN THROUGH SCREEN DIRECTLY TO CONVEYER#69(SIZE LESS THAT 6MM) AND OVERSIZE COAL (ABOVE 6MM) GOING TO CONVEYER#64 THROUGH BUCKET ELEVATOR HAVING CAPACITY 65 TPH FOR RECRUSHING IN COAL IMPACTOR WITH FRESH COAL. CLOSE COAL CIRCUIT IS RUNNING DURING COAL FEEDING IN B#2. FINALLY COAL IS GOING TO THE BUNKERS THROUGH COMVEYER#70, DAYBIN CONVEYER AND TRIPPER CONVEYER.
CHP FLOW CHART
FLOW DIAGRAM FOR COAL HANDLING PLANT
Through Feeder Through Feeder
YES
NO NO
YES
B#1 & 2 B#3
Wagon Tippler (Crushed to less than 100 mm size)
Newton In Motion Weighbridge for Weigment of wagons
Caol from Collieries Size:- Less than 500mm
100mm to 75mm and less than 25mm size coal collected in & out side the coal shed for Boiler#1 &
3
75mm to 25mm size coal collected in side
the coal shed for Boiler#2
Reclaim Conveyor
Conveyor#64
Vibro Feeder (W) For Boiler#1 & 3(51)
Vibro Feeder (E) For Boiler#2(48)
Boiler#1 & 3 Coal Impactor (100
MT/HR)
-20mm size
Boiler#2 Coal Impactor (240 MT/HR)
-8mm size
BUCKET
ELEVATOR
Bunkers to fill
Conv#65
Vibro fdr#49 Vibro fdr#50
51