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Pulverizer Performance
Grind Fuel To Required Fineness Dry Fuel According to the Fuels Drying Characteristics Transport Fuel To Furnace
Pulverizer Performance
Thermal Capacity
Throughput in Lbs/Hr that the pulverizer can dry
The Actual Capacity of a Pulverizer is the Lower of the Mechanical or Thermal Capacity
Pulverizer Performance
Factors Affecting Pulverizer Mechanical Capacity Raw Fuel Grindability Required Product Fineness Fuel Moisture Content Available Airflow Available Power
Pulverizer Design
Mechanical Capacity Determination Increasing Recirculation Load
Lower HGI Higher Fineness Higher Moisture (High Rank Fuel)
Pulverizer Performance
FINENESS CAPACITY FACTOR
HIGH
HIGH
Pulverizer Performance
Western Fuel (Sub C) Mechanical Capacity Adjustment Hardgrove Grindabilty - Western Fuel Measured HGI Not An Absolute Indicator of Difficulty to Grind Product Fineness - Due to High Reactivity, Western Fuel Fineness Levels Can Lower Than Eastern Coal With Low Unburned Carbon Levels Moisture - There Is No Capacity Correction For Western Fuels Due to Drying Characteristics
Pulverizer Performance
Pulverizer Performance
Coal Drying Characteristics
High Rank Fuels
Eastern Bituminous
Raw Fuel Moisture Ranges 2% - 16% Pulverized Fuel Moisture Range 1% - 2 % Constant Outlet Moisture vs. Inlet Moisture Typical Pulverizer Outlet Temperature 180 oF
Pulverizer Performance
Coal Drying Characteristics
Low Rank Fuels
Sub Bituminous
Raw Fuel Moisture Range 21% - 31% Pulverized Fuel Moisture Range 15% - 24% Outlet Moisture Varies With Inlet Moisture, Air Fuel Ratio, Outlet Temperature Typical Maximum Pulverizer Outlet Temperature 150 oF
Lignite
Raw Fuel Moisture Up To 39% Pulverized Fuel Moisture Range 15% - 25 % Outlet Moisture Varies With Inlet Moisture, Air Fuel Ratio, Outlet Temperature Typical Maximum Pulverizer Outlet Temperature 150 oF
Pulverizer Performance
Pulverizer Thermal Capacity is Determined Using a Heat Balance Mathematical Model
Required Heat = Heat Absorbed in Mill + Heat in Air Leaving Available Heat = Primary Airflow x Air Temperature x Cp
Mill
Losses
Pulverizer Performance
Mill Thermal Prediction/Selection Using Heat Balance Algorithm
Inputs
Required Coal Flow - Given Inlet Moisture - Analysis Outlet Moisture - Curves/Algorithm Available Airflow - Standard Outlet Temperature - Standard
Outputs
Inlet Temperature Relative Humidity Dew Point Coal Line Velocity
Pulverizer Performance
The Actual Capacity of a Pulverizer is the Lower of the Mechanical or Thermal Capacity
80000 70000 60000 50000 40000 30000 20000 10000 0 C1 - EBit A - 25.5% B - 23.5% C - 27.2% D - 29.9% E - 31%
Pulverizer Performance
Pulverizer Performance Issues With PRB Switch
30% Increase in Required Coal Flow Loss of Spare Mill Adequate Available Milling Power Adequate Primary Airflow Adequate Primary Air Temperature
Pulverizer Performance
Typical Milling System Arrangements Vertical Spindle Mills
ALSTOM Power (CE)
RB, RS, RPS, RP, HP Suction & Pressurized EL, E, MPS Primarily Pressurized MB, MBF Primarily Pressurized MPS Primarily Pressurized
Horizontal Mills
Foster Wheeler
Tube Suction & Pressurized Tube, Atrita Suction & Pressurized
Foster Wheeler
Pulverizer Performance
Pulverizer Performance
Pulverizer Performance
Potential Plant/Pulverizer Modifications For PRB Switching
Mill Replacement Classification Improvement
Dynamic Classifier Wing Tip Vane Wheel w/Int. Deflector Liner
Pulverizer Performance
High Speed Fan Arrangement
High Speed Motor With Direct Coupling
New High Speed Higher Capacity Motor New Mill Gearing New Forced Cooled Fan Bearing Assembly New Tungsten Carbide Lined High Efficiency Fan New Fan Casing Liner System
Pulverizer Performance
Pulverizer Performance
High Speed Fan Arrangement
Single Standard Speed Motor With Gearbox
New Higher Capacity Motor If Present Motor Lacks Margin New Exhauster Gearbox New Forced Cooled Fan Bearing Assembly New Tungsten Carbide Lined High Efficiency Fan New Fan Casing Liner System
Pulverizer Performance
Case Study - Modified ALSTOM 703 RS Milling System
Drivers Fuel Switch for Emissions Load Regain Modification Scope Dynamic Classifier 1000 BHP High Speed Motors Mill Blue Print Direct Fired Primary Air Heaters TFS2000R
Pre Mod Post Mod Max. Coal Flow 60,000 84,000 MW 265 273 Fuel Type EBIT/Sub C Blend Sub C 200 Mesh Fineness 60 76 50 Mesh Fineness 4 0.1 Airflow 57,000 88,000 Coal Spillage 50 0 Underbowl Press. -1 -1.88 Power - Amps 54 121 Nox 0.45 0.15
RESULTS Unit Currently Able To Attain Boiler MCR On 100% Sub C With 4 of 5 Mills In Operation
Pulverizer Performance
Case Study - Tube Mill Replacement
Drivers Fuel Switch for Emissions Load Regain Modification Scope (6) HP Mills For (3) Suction Tube Mills Static Classifiers Hot PA Fans RSFC Low Nox Burner System RESULTS Unit Currently At Boiler MCR On 100% Sub C With of 5 of 6 Mills In Operation
Mill Type Pre Modification Ball Tube Pre Modification Ball Tube Post Modification Vertical Spindle
200 Mesh Fuel Fineness NOX Illinois N/A 0.44 Sub C 65% 0.15 Sub C 70% < .2
Pulverizer Performance
Case Study - Tube Mill Replacement
Drivers Fuel Switch for Emissions Load Regain Modification Scope (6) HP Mills For (3) Suction Tube Mills Static Classifiers Hot PA Fans RESULTS Unit Currently Under Construction Expected MCR With 100% Sub C On 5 of 6 Mills In Operation
Mill Type Pre Modification Ball Tube Pre Modification Ball Tube Post Modification Vertical Spindle
200 Mesh Fuel Fineness NOX Illinois N/A 0.7 Sub C 65% 0.4 Sub C 70% 0.4
Pulverizer Performance
Case Study - Vertical Spindle Mill Replacement
Drivers Fuel Switch for Emissions Load Regain Modification Scope (8) HP Mills For (8) Pressurized Mills Dynamic Classifiers PA Fans Air Heater Modifications Boiler Modifications (Delayed 2007) RESULTS Unit Currently Has 8 Mills Installed With 8 Of 8 Mills Operational Boiler MCR Expected On 100% Sub C With 7 of 8 Mills In Operation After Boiler Modifications
MW 800 800
Coal Flow Fuel Lbs/hr 30% Sub C 92,000 100% Sub C 141,700
Mills in Service 7 of 8 7 of 8
Pulverizer Performance
Case Study - Vertical Spindle Mill Modification 803 RS
Drivers Fuel Switch for New SOX Emissions Load Regain Modification Scope High Speed Fan w/Variable Speed Control (Separate Drive Motor) Direct Fired Primary Air Heaters Dynamic Classifiers (1992) TFS2000R (1992) RESULTS Unit Currently Operational in SOX Compliance Boiler MCR On 100% Sub C With 5 of 5 Mills In Operation
Pulverizer Performance
Developing Technologies Primary Air Flow Control
Variable Speed Exhauster Fan Combustion Airflow Management
Purpose
Minimize Risk of Pulverizer Explosions Safely Control Pulverizer Fires
Design
Governed by NFPA Code Requirements Various OEM Designs Using Different Interpretations of Code ALSTOM Approach is Conservative Interpretation of Code/Conservative Design Design Not Affected by Coal Rank - i.e. Eastern Bit vs. PRB
A pulverizer tripped under load shall be inerted and maintained under an inert atmosphere until confirmation that no burning/smoldering fuel exists in the pulverizer, or the fuel is removed.
Ignition Source
ALSTOM Approach
Standard Flow Through Steam Inerting/Clearing System Currently Developing Dust Suppression System
Ignition Source
40
S T M F L O W K L B S / H R
30
15 20 10 5 0 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 10
TIME (SECONDS)
MILL 02 STEAM FLOW
Ignition Source
Ignition Source
Pulverized Fuel in Suspension Sufficient Oxygen Intermixed With Coal Particles Sufficient Ignition Source Lower Oxygen To Prevent Particle to Particle Combustion Knocks Fuel Out Of Suspension Provide Some Degree of Fire Extinguishing Mill Cooling
Classifier Approx. 7 Nozzles At 4 GPM/Nozzle Millside Approx. 6 Nozzles At 8 GPM/Nozzle Air Inlet Approx. 3 Nozzles At 10 GPM/Nozzle Mill Trip Feeder Trip Interruption in Raw Fuel Feed
Can Be Manually Activated (Normal Starts and Stops) Water Nozzles Kept Clean With Seal Air During Normal Mill Operation