Documente Academic
Documente Profesional
Documente Cultură
Acknowledgement
At the onset I must thank all the people at BBGS without whose active support
this project would not have materialized. In view of this I would like to extend my
sincere thanks and gratitude to everyone who has supported me during the
UNMESH 12 internship programme.
I am highly indebted to Mr. Souvik Dutta for his guidance and constant
supervision as well as for providing necessary information regarding the project &
also for his support in completing the project. I would also thank Mr. Kaushik
Chaudhuri, Mr. Suman Sengupta, Mr. Debashish Chatterjee, Mr. Sharnath
Banarjee, Mr. Sk. Sabir Ali, Mr. Tapas Ghosh and Mr. Subhendu Ghosh for their
constant support and guidance.
I would also like to express my special gratitude and thanks to industry people
and CESC HRD for giving me such attention and time.
My thanks and appreciation also goes to my parents, family and professors
from IIT Kharagpur who have willingly helped me out to achieve my objective.
Certification
Date:
Signature
Mr. Souvik Dutta
Deputy General Manager
Budge Budge Generating
Station , CESC
Objective
1).Improvement of BBGS Unit 3 boiler efficiency by
reducing un-burnt in ash.
2). Reduction of BBGS Unit 3 auxiliary consumption
power by reducing boiler feed pump power
consumption
Content
1.
2.
Introduction
Improvement of BBGS Unit 3 boiler efficiency by reducing un-burnt in ash.
3.
4.
Conclusion
Introduction
Energy projects are among the most capital intensive infrastructure investments. Decisions
made today will form our lives for decades, and it is important that these decisions are based on facts
and a proper economic assessment of available options. The global power sector is facing a
number of issues, but the most fundamental challenge is meeting the rapidly growing demand
for energy services in a sustainable way, at an affordable cost and in the environmentally
acceptable manner. This challenge is further compounded by the fact that the major part of the
increase in demand for power and hence in the emissions in the future, will come from
developing countries, who strive to achieve a rapid economic development.
A power plant produces electrical energy and also consumes substantial amount of this
energy in the form of auxiliary consumption. Auxiliary power comprises the power consumption
by all the unit auxiliaries as well as the common station requirement such as station lighting, air
conditioning etc. Plant auxiliaries include all motor-driven loads, all electrical power
conversion and distribution equipment, and all instruments and controls. Therefore Auxiliary
power in a power plant can define in three categories of auxiliary systems.
1. Drive power components such as pumps, fans, motors and their power electronics
such as variable frequency drives. These provide drive power for fuel handling, furnace draft,
and feed-water pumping. These systems and components will be referred to as Drive power.
2. Electrical power systems conversion, protection, and distribution equipment,
excluding motors and variable-frequency drives. This includes power transformers and LV and
MV equipment. These systems and components will be referred to as Electric Power Systems.
3. The instruments, control, and optimization systems. These provide boiler-turbine and
other control functions. These systems and components will be referred to as Automation
This auxiliary equipment has a critical role in the safe operation of the plant and
equipments used for auxiliary power are varying for different types of power plant. Reduction
of auxiliary power consumption could thus help increase the efficiency of a power plant.
Temperature
Time
Turbulence
While various losses are controlled by theoretical and metallurgical restriction the
combustion losses are due to un-burnt carbon. Un-burnt carbon is carried with either the
bottom ash or the fly ash. Insufficient time or insufficient oxygen can also lead to carbon
monoxide formation which is also a part of combustion losses. While various other losses are
difficult to reduce the combustion losses can be reduced significantly by optimizing the
operation conditions. The PF fineness of coal plays a significant part in un-burnt carbon
percentage control. The PF fineness is measured according to standards set by ASTM and is a
primary measure of the fineness of the fuel and consequently the time required for
combustion.
Un-burnt in ash can also be reduced by reducing the PA flow. The PA flow is used to
carry pulverized fuel to the boiler, when the PA flow is reduced the velocity of coal going into
the furnace is reduced, consequently giving the coal particles more time to burn.
Unit
Value
Carbon
40.16
Hydrogen
2.59
Nitrogen
1.02
Oxygen
5.39
Sulphur
0.44
Moisture
1.85
Ash
48.55
TOTAL
100
kCal/kg
4020
Coal analysis
GCV
During boiler efficiency test flue gas is measured with flue gas analyzer at APH outlet and it is
given below.
The Air heater leakage percentage at the SAH is computed by following equation.
% AHL =
Where
%AHL - Air heater leakage, percentage gas flow entering air heater
O2outlet - Oxygen at air heater outlet on a dry basis, measured, %
O2inlet
21 -
Oxygen, %
Leakage,%
SAH Inlet
305
2.6
2.0
SAH Outlet
146
Description A pass
Description B pass
3.0
0
Oxygen, %
Leakage,%
SAH Inlet
322
2.4
3.0
SAH Outlet
152
3.0
10
Observation:
here is an increase in oxygen percentage, indicating air leakage
Towards assessing the performance of air heater, the air and gas temperatures have been
measured. The effectiveness of the heater is given below:
The corrected flue gas outlet temperature from the APH is computed by the following equation.
Corrected gas outlet temperature (TGONI)
TGONI
Where,
AL
Cpg
Cpa
TAI
TGO
=
=
=
=
=
TGONI
= 148.27 0C
The Corrected gas outlet temperature (TGONI) at outlet of SAH B
TGONI
11
Unit
APH A
APH B
O2 at APH inlet
2.6
2.4
O2 at APH outlet
3.0
3.0
Air leakage
2.0
3.0
Cp of air
kCal/Kg/0C
0.24
0.24
146
152
37
36
Cp of flue gas
kCal/Kg/ C
0.23
0.23
148.27
155.63
The effectiveness (Gas Side Efficiency) of the air pre-heater is calculated by the following
equation
Flue Gas Analysis at APH outlet
Description
Unit
Boiler-3
149
Corrected Temperature
151.95
Ambient Temperature
35
DBT
35
WBT
29
Oxygen
CO2
16
CO
ppm
28
During boiler efficiency test fly ash and bottom ash sample is collected and the ash analysis
report is given below.
12
Unit
Boiler-3
Un-burnt
2.745
kg/kg of fuel
0.01133
Un-burnt
7.515
Carbon in bottom
kg/kg of fuel
0.0055
The procedure of calculation of un-burnt in both fly ash and bottom ash is described later in this
document.
Observation:
Boiler efficiency:
Boiler efficiency is calculated by indirect method based on flue gas, coal and ash analysis report
as given below,
The boiler efficiency is calculated by the indirect method and is as follows.
Theoretical Air requirement = [(11.6 C) + {34.8 (H2 O2/8)} + (4.35S)]/100
(Kg / kg of fuel)
Where,
C
H2
O2
S
=
=
=
=
13
Theoretical Air requirement = [(11.6 40.16) + {34.8 (2.59 5.39 / 8)} + (4.35
0.44)] / 100 (kg / kg of fuel)
= 5.34 kg/kg of fuel
O2 %
------------------- x 100
(21 - O2 %)
3
--------------- x 100
(21 3)
16.67 %
AAS
Where,
M
Cpf
Ta
=
=
=
14
Where,
Cp
Where,
Mf
15
CO X C X 5744 x100
(CO + CO2) X GCV of Fuel
Where,
C
CO
CO2
=
=
=
0.0015 %
Percentage heat losses due to radiation and convection losses & unaccounted (Q) (assumed)
=
1.5 %
16
1.11%
= 0.24%
Sensible Heat Loss from Bottom Ash
=
Total mass of bottom Ash X 0.2 X (Tb - Ta) X100
GCV of Fuel
17
18
Un-burnt in ash: Fly ash is a byproduct of coal combustion and it contains many different
mineral matters such as carbon, iron oxide and Sulphur. Unburned carbon in fly ash is a major
index to determine the efficiency of coal combustion in a power plant. Fly ash with a high
volume of unburned carbon not only indicates poor combustion efficiency, which results in a
high emission of pollutants and higher fuel requirement, it also prevent power plants from
selling the coal fly ash to secondary markets for recycling. In order to ensure the combustion
efficiency and maintain low unburned carbon content in fly ash, the power industry is
constantly investigating the most effective way to monitor the unburned carbon in fly ash.
19
The following is the trend for the un-burnt in bottom ash for Unit-3 for the FY 2011-12:
20
21
The following is the trend for the un-burnt in bottom ash for Unit-3 for the FY 2011-12:
22
The higher values of the un-burnt in both fly ash and bottom ash could be due to various
reasons. One such reason could be related with PF fineness of coal. The PF fineness of the coal
might be low resulting in larger average surface area, leading to more un-burnt coal in ash. We
observe the PF fineness characteristics of various mills in Unit-3.
PF fineness is done using iso-kinetic sampling of coal from various mills.
The PF grading test is as follows
PF grading procedure
1. Air drying of sample is recommended if high moisture (>10%) coal is being fired or sieving is
not performed immediately after sample extraction. This is to prevent the coagulation of
sample on top of sieve screens which prevents particles to pass through screens and results in
non-representative coal fineness. Coagulation of coal sample usually appears as small "balls" of
coal on 100 Mesh screens. ASTM D-197 specifies drying at 18 27F above room temperature
until weight loss is less than 0.1% difference.
This step can usually been eliminated if the following criteria have been established:
Pulverizer Discharge temperature above 160F
Fuel moisture is moderate
Collected samples are placed in air-tight Ziploc bags
Sieving is performed immediately after extraction
No coagulation of coal is observed during sieving
2. Remove 50 grams of coal from the sample. This is done by using an ASTM riffler or by
rolling the sample (usually between 200 g and 800 g). We advocate the riffler method which
is cleaner and more efficient. A 50 gram sample can not be simply scooped or spooned from
the whole sample; this may result in a disproportionate quantity of fine or coarse particles. If
sample is not exactly 50 g, be sure to weigh and record initial sample weight. The figure below
illustrates a coal riffle as specified by ASTM D 197-87. Plot the percentages passing each sieve
to the Rosin and Rammler equation. The percent passing 50, 100 and 200 Mesh should fall on a
straight line. If the plotted line is not linear, the sample is non-representative and must be
extracted. The Figure below illustrates representative coal fineness plotted against the Rosin
and Rammler equation. Non-representative sampling is the result of one of following:
23
50 g
R1g
_____________
R2g
_____________
R3g
_____________
R4g
_____________
R5g
_____________
% Passing 50 Mesh
50.00
(50.00 - R1 ) 100
24
50.00
% Passing 100 Mesh
% Recovery
25
Figure 9
27
Using this procedure the PF grading of Mill 3 D was calculated and the following were the
observations
Category
Time
Weight
15 minutes
30.38 grams
+2 minutes
4.12 grams
+2 minutes
3.12 grams
+2 minutes
0.92 grams
+2 minutes
0.57 grams
Total weight
39.11 grams
Weight present
Percentage
+52
0.05
.1
+100 , -52
2.12
4.24
+200 , - 100
8.72
17.44
-200
39.11
78.22
The following is the trend of the PF fineness from various mills of BBGS unit #3
28
PF fineness grading
Sl No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Date
11-Mar-10
6-Apr-10
23-Apr-10
25-Apr-10
6-May-10
11-May-10
19-May-10
23-May-10
5-Jun-10
29-Jun-10
3-Jul-10
4-Aug-10
3-Sep-10
14-Sep-10
14-Oct-10
6-Nov-10
5-Dec-10
19-Jul-11
11-Aug-11
31-May-12
Average
52
0.16
0.6
0.28
0.24
0.14
0.2
0.22
0.14
0.56
0.36
0.6
0.32
0.28
0.52
0.72
0.38
0.76
0.84
0.5
0.48
0.415
29
-200
79.16
70.94
82.9
78.16
83.88
75.66
74.96
79.9
67.12
76.66
72.1
71.88
85.1
73.58
62.58
73.94
70
66.54
69.12
59.54
73.686
Sl No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
Date
11-Mar-10
25-Mar-10
30-Mar-10
6-Apr-10
23-Apr-10
25-Apr-10
6-May-10
16-May-10
23-May-10
9-Jun-10
29-Jun-10
8-Jul-10
26-Jul-10
8-Aug-10
9-Sep-10
3-Oct-10
6-Nov-10
15-Dec-10
1-Jan-11
15-Mar-11
3-Apr-11
20-Apr-11
6-May-11
22-May-11
8-Jun-11
24-Jun-11
10-Jul-11
28-Jul-11
14-Aug-11
29-Aug-11
13-Sep-11
18-Sep-11
28-Sep-11
29-Sep-11
15-Oct-11
30-Oct-11
12-Nov-11
24-Nov-11
52
0.08
0.3
0.16
0.82
1.38
1.08
0.66
0.18
1.14
0.64
2.16
0.58
1.12
0.66
0.64
0.68
0.1
1.3
0.32
0.78
0.84
1.08
1.6
1.02
0.7
1.32
1.12
0.96
0.62
0.56
1.58
1.5
0.86
0.86
1.22
1.04
0.78
0.88
30
-200
83.68
78.06
76.78
74.12
56.08
68.72
62.04
70.78
65.7
69.96
71.16
56.5
70.16
65.46
75.02
67.64
70.44
62.92
69.38
66.74
66.46
76.44
66.54
65.04
69.46
63.54
64.02
64.22
66.3
67.48
62.54
63.66
76
76
61.62
66.02
69.58
65.92
39
40
41
42
43
44
45
46
9-Dec-11
24-Dec-11
9-Jan-12
19-Jan-12
20-Feb-12
22-Apr-12
28-May-12
31-May-12
Average
0.92
0.06
0.16
0.2
0.16
0.18
0.14
0.1
9.8
4.64
6.12
7.72
6.8
5.6
6.68
5.02
21.78
19.94
22.56
26.04
29.92
21.06
23.56
20.42
67.5
75.36
71.16
66.04
63.12
73.16
69.62
74.46
0.766
8.987
21.712
68.535
31
Aver
Sl No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
Date
2-Mar-10
26-Mar-10
24-Apr-10
30-Apr-10
14-May-10
21-May-10
23-May-10
12-Jun-10
29-Jun-10
6-Jul-10
11-Jul-10
10-Aug-10
14-Sep-10
18-Sep-10
3-Oct-10
20-Nov-10
18-Dec-10
6-Jan-11
2-Feb-11
15-Feb-11
14-Mar-11
3-Apr-11
21-Apr-11
7-May-11
11-Jun-11
26-Jun-11
12-Jul-11
30-Jul-11
15-Aug-11
30-Aug-11
9-Sep-11
17-Sep-11
17-Sep-11
28-Sep-11
3-Oct-11
19-Oct-11
52
0.68
1.12
1.98
1.9
2.02
0.88
2.12
2
0.4
1.78
2.46
2.22
1.28
1.88
3
0.78
1.02
3.76
2.06
1.22
1.76
0.22
1.8
0.82
2.32
2.74
2.04
1.66
3.1
2.74
1
4.14
4.5
3.32
3.3
3.4
32
-100/200
16.28
18.66
21.08
20.46
18.84
19.94
24.8
21.44
17.28
17.36
24.62
23.22
20.66
24.88
21.12
16.98
18.84
24.3
20.76
18.08
19.52
26.16
19.36
24.66
24.04
22.2
19.5
20.38
21.44
19.8
20.36
21.66
24.5
25.48
22.5
22.66
-200
76.4
71.76
64.44
65.66
70.48
70.46
57.66
64.94
75.92
69.64
60.9
62.92
65.16
61.04
60.88
74.36
72
53.92
63.48
70.12
67.22
65.32
67.78
60.46
58.14
59.74
62.24
62.92
59.8
63.9
68.88
59.02
54.5
53.66
58.56
56
37
38
39
40
41
42
43
44
45
5-Nov-11
20-Nov-11
6-Dec-11
20-Dec-11
4-Jan-12
15-Jan-12
4-Feb-12
22-Feb-12
12-Apr-12
Average
1.98
1.28
2.74
0.1
0.18
0.1
0.22
0.32
0.2
1.79
17.52
11.04
18.06
5
6.68
6.12
8.54
8.48
3.98
11.953
27.5
22.7
26.32
25.94
27.3
25.96
33.22
34.2
24.82
22.484
33
53
64.98
52.88
68.96
65.84
67.82
58.02
57
71
63.773
Sl No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
Date
11-Mar-10
15-Mar-10
26-Mar-10
27-Mar-10
9-Apr-10
19-Apr-10
29-Apr-10
22-May-10
23-May-10
2-Jun-10
15-Jun-10
29-Jun-10
8-Jul-10
18-Aug-10
14-Sep-10
15-Sep-10
11-Oct-10
9-Nov-10
25-Dec-10
11-Jan-11
13-Jan-11
4-Feb-11
17-Mar-11
6-Apr-11
24-Apr-11
10-May-11
25-May-11
10-Jun-11
25-Jun-11
11-Jul-11
29-Jul-11
16-Aug-11
31-Aug-11
9-Sep-11
16-Sep-11
18-Sep-11
28-Sep-11
34
-100/200
15.94
22.74
21.38
20.9
23.4
19.42
25.68
21.66
24.24
17.98
23.42
16.04
25.76
20.44
20.86
21.48
17.04
18.34
22.04
19.4
27.72
21.88
22.8
18.4
18.16
22.74
20.28
19.54
22.52
20.84
24.7
21.86
22.28
23.86
23.94
31.88
27.52
-200
68.22
58.84
66.14
67.84
59.9
60.8
50.36
53.8
49.94
67.04
51.94
80.46
63.78
74.36
73.44
75.14
78.88
78.48
74.88
74.46
65.08
70.44
71.9
71
69.52
70.8
73.68
74.82
70.62
71.56
68.56
73.26
70.84
70.06
69.38
54.88
62.72
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
29-Sep-11
2-Oct-11
17-Oct-11
3-Nov-11
17-Nov-11
4-Dec-11
16-Dec-11
1-Jan-12
14-Jan-12
3-Feb-12
17-Feb-12
17-Mar-12
2-Apr-12
18-Apr-12
2-May-12
31-May-12
5-Jun-12
Average
0.6
0.34
0.1
0.02
0.12
0.16
0.16
0.1
0.22
0.12
0.22
0.16
0.2
0.14
0.16
0.1
0.1
0.982
9.16
8
4.82
4.16
7.36
3.9
4.62
6.1
9.92
7.84
5.68
7.44
8.32
7.26
5.96
4.24
2.5
8.155
27.52
24.36
23.86
22.76
28.6
21.74
22.5
24.34
29.22
28.46
23.22
26.96
28.88
26.5
22.4
17.44
13.3
22.614
62.72
67.3
71.22
73.06
63.92
74.2
72.72
69.46
60.64
63.58
70.88
65.44
62.6
66.1
71.48
78.22
84.1
68.249
Sl No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
Date
11-Mar-10
7-Apr-10
9-Apr-10
10-Apr-10
24-Apr-10
30-Apr-10
10-May-10
16-May-10
20-May-10
18-Jun-10
12-Jul-10
16-Jul-10
22-Aug-10
14-Sep-10
22-Sep-10
3-Oct-10
12-Nov-10
13-Jan-11
6-Feb-11
22-Apr-11
8-May-11
23-May-11
24-May-11
9-Jun-11
5-Jul-11
26-Jul-11
12-Aug-11
27-Aug-11
9-Sep-11
19-Sep-11
24-Sep-11
28-Sep-11
28-Sep-11
29-Sep-11
29-Sep-11
13-Oct-11
29-Oct-11
16-Nov-11
27-Nov-11
52
0.48
1.8
2.94
0.8
3.86
7.24
5
8.82
7.62
0.66
1.78
0.58
0.4
0.48
0.6
3.62
0.58
0.6
0.36
1.32
0.62
0.16
0.84
0.76
1.16
0.82
0.82
0.8
1.22
1.48
1.04
1.6
1.6
1.6
1.6
2.2
1.1
2.2
0.04
36
-200
76.02
62.96
62.18
71.92
53.86
37.4
59.68
55.46
46.38
70.64
62.02
66.44
75.62
75.8
62.4
57.2
71.6
68.56
72.44
68.92
64.06
66.3
72.84
72.76
72.94
66.16
65.82
69.14
68.82
66.1
71
62.3
62.3
62.3
62.3
63.3
67.92
60.42
72.8
40
41
42
43
44
45
46
14-Dec-11
16-Jan-12
9-Feb-12
13-Apr-12
4-May-12
6-Jun-12
7-Jun-12
Average
0.9
0.46
1.26
1.96
1.12
0.9
0.9
1.711
8.48
7.96
10.16
11.62
7.8
8.9
8.9
11.115
19
21.8
24.46
21.54
19.58
20.18
20.18
21.326
71.62
69.78
64.12
64.88
71.5
70.02
70.02
65.848
From the above trends we observe Mill 3A PF fineness decreasing over the past few
months, the mill was subsequently shut down for overhauling and maintenance.
37
Principal Reducing the PA flow into the mill would reduce the velocity of coal going into the
furnace, which would give coal more time for combustion. Consequently this
would mean lower un-burnt carbon in ash.
Procedure The PA flow set point in general operation for Unit #3 at BBGS is about 90 TPH to
each mill making the total PA flow set point 360 TPH. This set point was reduced
to 80 TPH to each mill making the total PA flow about 320 TPH. Ash samples were collected for
both these set point conditions.
Observation PA Flow
360 TPH
320 TPH
4.91%
2.59%
The net reduction in un-burnt carbon in ash is calculated below (assumption 85% ash is fly ash
remaining is bottom ash).
Reduction
= (10.03 4.91) x 15/100 + (2.39 2.59) x 85/100
= 0.598 % un-burnt reduction is ash
Coal Savings
= 0.435 TPH
= 3,814,923.06 Kg / year
= Rs 3,37,54,744.94 / year
38
Booster Pump
Cent Horiz Single Stage
891 TPH
9.15 kg/cm2
1406 rev/min
80.5 %
308 KW
4.3m
Press stage
Cent Horiz
892 TPH
191.3 kg/cm2
5730 rev/min
81 %
6392 KW
4.9m
Duplex
80 mesh
185 micron
170 C
The Boiler Feed pump and the de-aerator are strategically placed so as to provide
sufficient suction pressure for the BFP. This is done by placing the de-aerator at a height (22.5
m) and then placing the BPF right under it at ground level.
The BFP used in BBGS Unit 3 has hydraulic coupling with scoop control to vary the
speed of the driven shaft. In hydraulic coupling pumps torque transmitted between the driverdriven shaft is varied by varying the oil levels using scoop control. Typical efficiency of a
hydraulically coupled motor is about 98% .
1. Operating the feed control valves in 3 element control and the BFP scoop would in DP
control mode. The advantage of operating FCS valves in 3 element control and BFP in
scoop is its quick response to large fluctuations in load.
2. Operating the BFP scoop in 3 element control mode. The advantage of this process is
the its energy efficient working scheme where there is least amount of throttling loss
across the valves of the feed control station.
The energy saving were noted for the following control conditions
i.
ii.
iii.
BFP in scoop control with :a. 1 full load valve of feed control station completely open and the other valves
closed.
b. 1 full load valve and 1 low load valve open.
c. all valves of feed control station completely open.
41
Date
30-0512
Time
1000
1020
1040
1100
1100
1120
1140
1200
1400
1420
1440
1500
1500
1530
1600
1600
1630
1700
Avg.
Average
FCS DP
Load
suction
FCS DP
832.15
815.7
837.05
850.55
851.53
1.769
1.927
1.85775
1.927
1.808
1.808
3.534
3.087
3.456
3.55
2.239
2.205
2.2275
2.202
2.264
2.264
0.568 1.13333
0.568
0.568
0.512 0.49933
0.418
Average
load
259.5
260.36
259.9725
258.32
261.71
261.71
261.98
262.12
263.05
261.74
260.71
261.16
261.0525
260.98
261.36
261.36
263.04 261.9367
261.41
261.41
263.37 262.12
261.58
Frequency
Total
power
BFP aux %
of total
generation
49.7
5.3636
2.06314
49.63
5.684
2.16847
49.6
5.3848
2.06273
49.73
5.2572
2.00705
49.93
5.143
1.96208
At 250 MW generation:
The BFP at 1.8 DP set point power consumption = 5157.85 units/ hour
BFP scoop in 3 element control power consumption = 4905.2
(With 3 FCS V/V FULLY OPENED)
units/hour
43
Conclusion
Reducing the PA flow into the mills reduces the un-burnt carbon losses significantly.
When the coal quality is good it would require lower time and turbulence to burn properly as
compared to a bad grade of coal. Reduction of PA flow into the mill increases the time coal has
for combustion, however the turbulence is also partly reduced. Lower grades of coal might not
be able to optimally burn in low turbulence condition. For down shot boilers, increasing the PA
flow would increase the velocity of coal flowing into the furnace, leading to higher un-burnt in
bottom ash. In corner fired boilers higher velocity would mainly reduce the coal-air mixing time,
leading to poorer combustion.
It was found that when the BFP scoop is put in 3- element control, the loss that was
occurring at the feed control station valves is reduced significantly, making this a cost efficient
method. However as compared to the conventional method of putting the feed control station
in 3- element control and the BFP scoop controlling the DP set-point across the feed control
station, the response time required in the higher. Thus when the load fluctuates rapidly for a
unit, the conventional method becomes a little more bankable. For normal operation however
the energy savings by putting BFP scoop in 3- element control is significant.
44