Presentation Titleindianpowerstations.org/IPS 2013 Presentations/Day-1 at Maneksha… ·...

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Presented by :

Kalyan Panda

Punarbasu Bhattacharya

13/2/2013


Background

2

Coal Sourcing/ Market dynamics are undergoing disruptive changes. Future

positioning of Utilities should be based on the ability to design large steam

generator capable of tolerating a wide band of Fuel Quality variation from

Multiple Source(s) , Multiple Mine(s) and Multiple Countries as compared to

the existing practice of design FUEL specific/Mine Specific/Country Specific

The success of Power Project in Future will largely depend upon how

quickly and effectively it adapts to the changed scenario.


Coal Classification-ASTM

3


Fuel Property Variation

4

0

10

20

30

40

50

60

70

a b c d e f g h i j k l m n o p q r s t u v w x y

Fixed Carbon

Volatile Matter

Ash

Total Moisture

Indian Coal a

Indian Coal b

Indian Coal c

Indonesian Coal d

Indonesian Coal e

Indonesian Coal f

Indonesian Coal g

USA Coal h

USA Coal i

Afghan Coal j

Hungary Coal k

Hungary Coal l

Czech Coal m

Mongolia Coal n

South African Coal o

China Coal p

German Coal q

Polish Coal r

Brazil Coal s

Colombian Coal t

Australian Coal u

Chile Coal v

Korean Coal w

South African Coal x

Australian Coal y



5

0

1000

2000

3000

4000

5000

6000

7000

8000


GCV [Kcal/Kg] Indian Coal a

Indian Coal b

Indian Coal c

Indonesian Coal d

Indonesian Coal e

Indonesian Coal f

Indonesian Coal g

USA Coal h

USA Coal i

Afghan Coal j

Hungary Coal k

Hungary Coal l

Czech Coal m

Mongolia Coal n


China Coal p

German Coal q

Polish Coal r

Brazil Coal s

Colombian Coal t

Australian Coal u

Chile Coal v

Korean Coal w


Australian Coal y



6


Moisture-Variation

7

0

5

10

15

20

25

30

35

40

45

50


Total Moisture Indian Coal a

Indian Coal b

Indian Coal c

Indonesian Coal d

Indonesian Coal e

Indonesian Coal f

Indonesian Coal g

USA Coal h

USA Coal i

Afghan Coal j

Hungary Coal k

Hungary Coal l

Czech Coal m

Mongolia Coal n


China Coal p

German Coal q

Polish Coal r

Brazil Coal s

Colombian Coal t

Australian Coal u

Chile Coal v

Korean Coal w


Australian Coal y


Sulphur, Nitrogen - Variation

8

0.00

0.50

1.00

1.50

2.00

2.50

3.00

3.50

4.00


Sulpher

Nitrogen

Indian Coal a

Indian Coal b

Indian Coal c

Indonesian Coal d

Indonesian Coal e

Indonesian Coal f

Indonesian Coal g

USA Coal h

USA Coal i

Afghan Coal j

Hungary Coal k

Hungary Coal l

Czech Coal m

Mongolia Coal n


China Coal p

German Coal q

Polish Coal r

Brazil Coal s

Colombian Coal t

Australian Coal u

Chile Coal v

Korean Coal w


Australian Coal y


Ash Property - Variation

9

0

10

20

30

40

50

60

70

80


% o

f in

co

al

SiO2

Al2O3

Fe2O3

CaO

MgO

Indian Coal a

Indian Coal b

Indian Coal c

Indonesian Coal d

Indonesian Coal e

Indonesian Coal f

Indonesian Coal g

USA Coal h

USA Coal i

Afghan Coal j

Hungary Coal k

Hungary Coal l

Czech Coal m

Mongolia Coal n


China Coal p

German Coal q

Polish Coal r

Brazil Coal s

Colombian Coal t

Australian Coal u

Chile Coal v

Korean Coal w


Australian Coal y



10

0.00

0.50

1.00

1.50

2.00

2.50

3.00

3.50

4.00


K2O

Na2O

Indian Coal a

Indian Coal b

Indian Coal c

Indonesian Coal d

Indonesian Coal e

Indonesian Coal f

Indonesian Coal g

USA Coal h

USA Coal i

Afghan Coal j

Hungary Coal k

Hungary Coal l

Czech Coal m

Mongolia Coal n


China Coal p

German Coal q

Polish Coal r

Brazil Coal s

Colombian Coal t

Australian Coal u

Chile Coal v

Korean Coal w


Australian Coal y



11

800.00

900.00

1000.00

1100.00

1200.00

1300.00

1400.00

1500.00


IDT [Deg.C] Indian Coal a

Indian Coal b

Indian Coal c

Indonesian Coal d

Indonesian Coal e

Indonesian Coal f

Indonesian Coal g

USA Coal h

USA Coal i

Afghan Coal j

Hungary Coal k

Hungary Coal l

Czech Coal m

Mongolia Coal n


China Coal p

German Coal q

Polish Coal r

Brazil Coal s

Colombian Coal t

Australian Coal u

Chile Coal v

Korean Coal w


Australian Coal y


Paradigm Shift

12

EXISTING

Fuel/ Mine specific

design - Linked mine/ Single

rank/Single location

Fuel security perception - Single Contract (CIL)

- Acquire Mines

domestic/overseas

Contracts- Guarantee

centric - Efficiency/APC/BMCR

Cost Centric Design

SHIFT

Unlimited fuel flexibility

- Multiple mines/ Multiple

ranks/ Multiple countries

Fuel security perception - Strategic tie-up for multi

location sourcing

Contracts – Function

Centric - Reliable/Safe/Optimal

operation

Optimal Design


Shift in Boiler Design

13

Parameters Current Future

Fuel Specific Design Narrow Range Wide Range

Tolerance to GCV

variation Low High

Slagging / Fouling

Index

Low / Medium

(Fuel -Specific) High

Acceptable Moisture

Limit 25 to 30 % Up to 50 %


FUEL SWITCH

Innovation @ Power Sector 14

Future Requirement

LARGER

FLEXIBILITY

…Message Box ( Arial, Font size 18 Bold) Innovation @ Power Sector 15

Future Requirement

WIDE FUEL

FLEXIBILITY &

HIGH

RELIABILITY

…Message Box ( Arial, Font size 18 Bold) 16

Fuel switch impact

Equipment Impact Possible

options

Steam Drum No -

Mud Drum No -

Separator (For

Once Through

Boiler Alloy

steel)

No -

Equipment

(Furnace) Impact

Possible

options

Width Yes Design furnace

dimension with

high slagging

coal

Height Yes

Depth Yes

Tube

Metallurgy No

Water wall

cleaning

system

Yes

-Design on high

slagging coal.

-Install water

canon etc.

Firing

System

Design

Yes

(Firing

System

design

differs for

low and

high VM

coal

Design boiler

with available

coal considering

low VM

Equipment (Piping) Impact Possible

options

Down-comer, riser etc and

other miscellaneous integral

piping

No

Equipment Impact Possible

options

Economizer

arrangement

Yes

Depends on fuel

fouling index and

erosion index.

Design based

on worst fuel

Equipment Impact Possible options

Rotary air

pre heater

(Basket

profile)

Yes

Selection on

-Worst ash

characteristics

-Space of additional

elements

-Hot end and cold end

soot blower.

-2 separate APH for

primary and

secondary to increase

operational flexibility

Equipment

Impact

Possible

options

SCAPH No except for very

high sulphur coal

…Message Box ( Arial, Font size 18 Bold) 17

Fuel switch Impact

Equipment

(Super heater) Impact Possible options

Arrangement Yes

Design super heater

arrangement/

cleaning system on

worst coal

characteristics

Area

Yes

(Super

heater

normally

sized with

low

moisture

and high

GCV coal)

Following design

tools are used to

control:-

1. Super heater

spray

2. Divided back

pass design

3. SH Gas

tampering

4. SH Gas bypass.

Tubes/ Header

metallurgy Yes

Super heater

cleaning

condition

Yes

Select SH cleaning

system based on

worst fuel

Equipment

(Re-heater) Impact

Possible

options

Re-heater

arrangement Yes

Design on

worst fuel

RH Spray Yes

-Operation

flexibility tool

-Steam to

steam

attemperator

RH Tube

metallurgy Yes

Re-heater

arrangement Yes


Boiler Non Pressure part-Effect

Equipment

(Firing

System)

Impact Possible options

Burner Yes Select on worst fuel

Oil System Yes Design on worst

fuel

Milling

system

Yes

Coal HGI

and

moisture

governs

mill

selection

-Milling system as

per coal band.

-Features like

furnace gas

recirculation,

-Additional heating

of PA

Bunker, Coal

pipe, mill

inlet pipe

design

Yes

Equipment

(Pollution

control

equipment)

Impact Possible

options

ESP

Yes

ESP design

depends on fuel

ash content and

ash resistivity

.

Equipment

(Ducting System)

Impact Possible

options

FD, ID, PA duct Yes

Additional flexibility

features gas

bypass/ Gas

recirculation

Yes

Equipment

(Miscellaneous

Components)

Impact Possible

options

Main structure No

Hot structure No

Hoppers No

Slings and support No

Low pressure piping No

Valves and instruments No

Equipment

(Ash Handling

and coal

handling)

Impact Possible

options

Ash handling

system design Yes

Coal handling

system design Yes

Designed

based on

maximum

coal

consumption

18


Fuel Switch - Current Situation

19

o During the life time of Boilers - Utilities have experienced operational constraints due

to fuel switch/source changes

o Numerous examples of boiler modifications Post commissioning

o Study of the modifications clearly reflects

− Cause and Effect approach adopted for solution deployment

− Each of these modifications/solutions were selected from repository of few fixes.

If these fixes are proactively incorporated at Design Stage

the boiler fuel flexibility will increase to a great extent.


Repository of Fixes/Design- Options

20

Type of fix Existing New unit

Improved SH Metallurgy

Larger Furnace Size

Flexibility Tool Divided Back pass

Flexibility Tool Gas Bypass / Gas Tempering

Furnace Gas Recirculation for PA Heating

Additional Mill

Additional Fan Margin

Additional Milling System

Coal Drying System

Water Cannon Vrs Soot blower

ESP Additional Margin

Application of Chemicals

Feasible

Not Feasible


Design Options- Cost Impact

21

3 to 4%

1 to 2%

1 to 2%

1 to 2%

3 to 4%

7 to 8%

1 to 2%

28-35%

55 to 65%

3 to 4%

2 to 3%

Larger furnace size

Improved SH metallurgy

Flexibility tool divided backpass

Flexibility tool gas bypass / gas tempering

Furnace gas recirculation for PA heating

Additional mill

Additional fan margin

Additional milling system

Coal drying system

Water cannon vrs soot blower

ESP additional margin

Enhanced

Base


FUTURE

NEED?

LARGER

FUEL

FLEXIBILITY

AT DESIGN

STAGE

STRATEGY

&

DESIGN

CHANGE

RELIABLE DESIGN

PRESENT TO FUTURE

22


Website: www.tatapower.com

Email ID:

[email protected]

mailto:[email protected]

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