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RodPifer
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CoalRecirculation
RawCoalFlow Product Output
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PrimaryAirControl CommonPAFan
ColdAir Duct Coalair TransportPipes Swing Valve Operators
Flow
Pitot Tubes
Shutoff Damper
Pulverizer
.3
CoalPropertiesAffectingPulverizerSelection
Basicratingformula
Correctedcapacity= BasecapacityxCgxCf xCm
Grindability (Cg)
Effectoncapacity Asaffectedbymoisture
Fineness(Cf)
Effectoncapacity Requirementsforfuelrank
Moisture(Cm)
Effectoncapacity Effectsonsurfaceandinherentmoisture
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B&WPulverizerCapacityCorrectionwith200 MeshFinenessStandardClassifier
1.2
1.0
.8
.6 50
60
70
80
90
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FinenessPercentPassing200Mesh
B&WPulverizerCapacityCorrectionDuetoMoisture
1.05 1.00
0.95
0.93
10
12
SurfaceMoisture(%byweight)
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Grindability Index
INDEXSCALE0100HGI B&WNOMINALINDEX50HGI TYPICALCOALS BITUMINOUS=4045HGI
PRB=5055HGI
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WaystoImproveFineness
AirFlow
Operateondesignair/coalcurve,periodicallyverified bypropercalibration Improveairdistributioningrindingzone
Rotatingthroat Throatorifice,plugs,inserts
Lower/eliminateunnecessarycontrolbias Readjustmentsforcoalchanges
Newthroatcastings(Differentvanethickness)
IncreaseClassifierSpeed
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AveragingPitot TubesforPrimaryAirDifferential
HighSide PressureTap LowSide PressureTap EqualizingLines
Detailofthepitot tubes
Pitot Tubes
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PossiblePitot TubeProblems
Newpitot tubesinstalledbutnotcalibratedortested Pluggedpitot tubes Cracksorholesinthepitot tubes Pitot tubeholeserodedorenlarged Leaksorplugsinthesignaltubingbetweenthepitot tubesandthepressuretransmitters Damsmissingorbroken Damsleftinwhennewpitot tubeswereinstalled
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WhatCouldBeWrongWithYourMill?
Primaryairflowissettoohighortoolowforpropermilloperation Primaryairflowissettoohighortoolowforgoodcombustion Primaryairflowmeasurementisincorrect Thecoalbeingburnedisnotwhatthemillwascalibratedtogrind
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WhyProperMillCalibrationIsImportant
Primaryairisneededtodrythecoalandtotransport thecoal Onlyuseenoughprimaryairtodryandtransportthecoal Properprimaryairflowhelpsmaintaintheproperbedof coalinthemill Themillisaballbearingwiththecoalbedactingasthegrease
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WhatHappensIfWeHaveTooMuchPA?
Coalfinenessisreducedasincreasedcirculationthroughtheclassifier increasesthechanceforlargeparticlestoblowthroughtheclassifier Higherthroatvelocityblowscoaloutofthebedintheringsthusreducing thelubricatingeffectinthegrindingzone Lesscoalbedinthegrindingzonecanresultinrippling,chippingand crackingoftheringsaswellasspalling andunevenwearontheballs Increasedvelocityattheburnercanmaketheflameunstableand increase theLOIandpossiblyNOx emissions
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WhatHappensIfWeHaveTooLittlePA?
Wetcoalattheburnermaynotigniteproperlyresultingin increasedslagging andincreasedLOI ReducedPAtemperatureattheburnermaycauseignition issuesresultinginincreasedslagging andincreasedLOI Theflamecouldpullbackintotheburner Couldhavecoaldribbleatlowermillloads
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ComparePulverizerPARequirementstoPARequirementsforthe RestoftheCombustionSystem
B&Wcoordinatesthesizeandperformanceoftheburnersandcoal pipingwith pulverizers SomeaftermarketburnersrequiremodificationstothePAflowto optimize combustionandemissions ChangingthecoalpipesizewillaffectminimumPAflowrequirements Pulverizers,coalpipes,andburnerscannotbeseenasseparateentities,as theyareallinterrelated
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PerformPrimaryAirCalibrationsProperly
Preparepulverizercontrolcurvebasedonthecoalbeingused CalibratethePA,Dp andMillDp pressuretransmitters Remove,inspect,cleanandleakcheckpitot tubes Isolateallsealair Fillrawcoalchutewithcoalandclosevalveatcoalsilo PerformPADp versusMillDp test;resultingcurvemustbea straightlinepassingthroughtheorigin Performcleanairtests(traverses)withPAflowsintherange expectedduringactualoperation UsemanometertomeasurePADp,MillDp,andPApressure Comparemanometerreadingstocontrolroomreadings Marktestpitot tubeforequalareas
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PerformPrimaryAirCalibrationsProperly(cont.)
MeasurePAflowineachcoalpipe CalculatetheKfactorforthepitot tubes Repeattestingat34PAflows AlloftheKfactorshouldbewithin5%oftheaverage ComparePAflowsineachcoalpipe;thisisconsideredto beagoodindicationofthecoalbalancebetweencoal pipes Preparefinalmillcontrolcurvesalsocalled CharacterizationCurvesorDirtyAirCurves
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WhatCanChangeYourKFactor?
Newormodifiedburners Newgrindingzoneinmill Significantcoalchange(changesPArange) ModificationstoPAfans(changeshowPAcomesofffan towardpitot tubes) ModificationstothePADucts(changeshowPAcomesoff fantowardpitot tubes)
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EffectofPRBonMillOperations
SignificantlyhigherPAtemperaturesrequiredduetohigh moisture inPRB SignificantlyhighervolumeofcoalfeedduetolowerBTUin PRBandlowerbulkdensityofPRB PRBisSticky itplugschutesandhoppersoranyplaceitfalls ontoaledgeorridge PRBlovestoburn itburnsintheboiler,itburnsinthe pulverizers,itburnsinthehoppers,itburnsinthepile,etc.
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EffectofPRBonMillOperations(cont.)
BlendsofbituminouscoalandPRBhavespecialproblems Grindingbituminouscoalisliketryingtobreakaboxfull ofmarbleswithasledgehammer GrindingablendofbituminouscoalandPRBisliketrying tobreaktheboxfullofmarbleswiththesamesledge hammeraftersomeonehasmixedinabunchoftennis balls PRBismorefriablethanbituminouscoal,soitwillhavea smallsizedistributioninthebunkers
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EffectofPRBonMillOperations(cont.)
Mostbunkersandsilosarehighlyeffectiveparticlesize segregators Thismeansaverageparticlesizeofthecoalwillvaryover abunkerloadingcycle Coalbulkdensitycouldchangedependingonhowsmall andlargeparticlesfittogetherinyourbunker Alsomoisturecontentcouldchangeassmallerparticles withmoresurfacetovolumeratiobringinmoresurface moisture
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CurrentB&WRollWheelPulverizerOperatingData
Thefollowingdata(providedbythecustomer)isrequiredbyB&W forusein determiningtheoptimumrotatingthroatportarea: 1.Normalfullloadcoalflowperpulverizer. 2.Normalfullloadairflowperpulverizer. 3.Pulverizerinlet/outletairtemperatureatabovenormalfullloadcoaland airflow. 4.Milldifferentialpressureatnormalfullloadcoalflow. 5.Millinletstaticpressureatnormalfullloadcoalflow (highsideofmilldifferentialpressure. 6.Maximumcoalflowatwhichpulverizerisoperated. 7.Minimumcoalflowatwhichpulverizerisoperated. 8.Numberofcoalpipesinserviceperpulverizer. 9.RawcoalHardgrove grindability. 10.Rawcoaltotal/surfacemoisture. 11.Rawcoalashcontent. 12.Rankoffuel. 13.Isthereasignificantamountofpyrites,rockortrampiron inthecoal? 14.Actualvs.desiredfineness. 15.Whatisthemajorgoalofinstallingrotatingthroatsi.e.;reducemillpressure drop, reducegrindingzoneerosion,improvefineness?
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RollWheelPulv.ClassifierAssembly
RawCoal
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PoorFinenessinaRollWheelPulverizer
Holeinclassifiercone Missingflapgate Flapgatestuckopen Lowspringpressure
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WaystoImproveRollWheelPulverizerFineness
Classifierlouversection
Outside/insidediameter Vaneangle Vanelength Numberofvanes Dischargecylinderlength Bottomplate(retention/spin)
Classifiercone
TopI.D. Coneangle Conevolume
Classifierdischarge(reduceSeal leakage)
Conicalbaffles Slopeddischargedoors Improveddoors(hingesfitup weighted)
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B&WRollWheelPulverizer ImprovementsUpdate
RodPifer
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B&WRollWheelPulverizerUpgrades
CastLowPressureDropRotatingThroats Wearesistor Tires Wearesistor LowProfileTires SmoothI.D.grindingsegments SegmentedYokeAirSeal Ceramiclinedswingvalveseats
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Wearesistor (Asymmetric)Tires
StandardTire Profile Substantialincreaseinusablewearmaterial comparedtooriginaldesigntires Usewithoriginaldesignstandardprofile grindingsegments Mountsonexistingwheel Nomodificationsrequired Wearesistor Tire Profile
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SmoothI.D.GrindingSegmentsforB&WRollWheelPulverizers
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CutAwayViewofSegmentedYASinPulverizer
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NewSegmentedYokeAirSeal(SplitLineShown)
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NewYASInstalledinPulverizer (MatchMarkedSegmentsShown)
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