Milling Systems

PRB Users Group

Milling System Performance Challanges & Operational Safety

Pulverizer Performance

Pulverizers are Process MACHINES and Are used to :

Grind Fuel To Required Fineness Dry Fuel According to the Fuels Drying Characteristics Transport Fuel To Furnace

Pulverizer Performance

Pulverizer Throughput Mechanical Capacity

Throughput in Lbs/Hr that the pulverizer can mechanically grind

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)

Decreasing Recirulation Load

Higher HGI Lower Fineness Lower Moisture (High Rank Fuel)

Pulverizer Performance
FINENESS CAPACITY FACTOR

Mechanical Capacity Determination

ALSTOM Applies Correction Factors For:
CAPACITY FACTOR

HIGH

Hardgrove Grindabilty - HGI Product Fineness Moisture

Eastern Bituminous Mid Western Bituminous

LOW FINENESS (% THRU 200 MESH)

HIGH

HGI CAPACITY FACTOR

HIGH CAPACITY FACTOR

LOW HARD HGI (HARDGROVE GRINDABILITY INDEX) SOFT

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

Factors Affecting Pulverizer Thermal Capacity

Fuel Rank Fuel Moisture Content Available Airflow Available Primary Airflow Temperature Desired Pulverizer Outlet Temperature

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

Mid Western Bituminous

Raw Fuel Moisture Ranges 6% - 26% Pulverized Fuel Moisture Range 4% - 7.5 % Constant Outlet Moisture vs. Inlet Moisture Typical Pulverizer Outlet Temperature 170 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

To Increase Thermal Capacity

Increase Mass Airflow Increase Air Temperature
Hot Air Seal Air Raw Coal Dry Pulverized Coal

Mill

Water Vapor Air

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%

Required Coal Flow Thermal Capacity

Mechanical Capacity Maximimized Thermal Capacity

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

Suction Style Systems More Prone to Operational Limitations

Lack of Fan Capacity Due to Higher Pressure Drop Lack of System Power w/Common Fan & Mill Motor

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

Babcock & Wilcox

Babcock Borsig (Riley)

Foster Wheeler

Babcock Borsig (Riley)

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

Increase in Primary Air Flow

High Speed Exhauster Fan (Patented) PA Fan Modification

Increase in Primary Air Temperature

Air Heater Upgrades Direct Fired Primary Air Heaters

Increase in Available Power

Larger Mill Motor or Separate Exhauster Motor

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

High Speed Fan Arrangement

Separate Motor With Gearbox
New Exhauster Motor Variable Speed Available New Right Angle Gearbox New Tungsten Carbide Lined High Efficiency Fan New Fan Casing Liner System

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

MW 350 250 360

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

MW 250 175 230

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

Pre Modification Post Modification

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

Pre Modification Pre Modification Post Modification

MW 390 280 390

Fuel Ebit. Compliance Sub Bit C Sub Bit C

Year 1993 2002 2003

SOX In Compliance In Compliance In Compliance

Pulverizer Performance
Developing Technologies Primary Air Flow Control
Variable Speed Exhauster Fan Combustion Airflow Management

On Line Fuel Line Balancing

Coal Line Distributors - Pressurized & Suction Pf Flo

Improved Operational Safety Systems

Fog & Swirl Inerting

Pulverizer Operational Safety

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

Pulverizer Operational Safety

NFPA Code

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.

Pulverizer Operational Safety

Hazardous Operating Conditions

Pulverizer Trip Raw Fuel Feeder Trip - Interruption in Raw Fuel Feed Restarting Hot Pulverizer With Charge of Coal

Pulverizer Operational Safety

Explosion Mechanics
Oxygen

Combustion Triangle Pulverized Fuel In Suspension

Ignition Source

Pulverizer Operational Safety

ALSTOM Approach
Standard Flow Through Steam Inerting/Clearing System Currently Developing Dust Suppression System

Pulverizer Operational Safety

Inerting Systems
Oxygen

Combustion Triangle Pulverized Fuel In Suspension

Ignition Source

Pulverizer Operational Safety

Steam Inerting
Inerting - to establish an oxygen content of 7% or less inside an off line pulverizer in a very short time period during conditions which are considered hazardous. Maintenance Flow Inerting - maintain an oxygen content of 7% or less inside an off line pulverizer after an inert atmosphere has been established. Low inerting flow is approximately one quarter of inerting flow. Clearing Flow- Coal transport flow rate - to safely transport the contents of the pulverizer to the furnace while maintaining an inert atmosphere within the pulverizer. This is used to safely remove the contents of the pulverizer prior to restarting or during fire fighting procedures.

Pulverizer Operational Safety

Steam Inerting Systems
25 20
M I L L 0 2

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

Pulverizer Operational Safety

Dust Suppression Systems
Oxygen

Combustion Triangle Pulverized Fuel In Suspension

Ignition Source

Pulverizer Operational Safety

Dust Suppression Systems With Inerting
Suppress Dust Inert Mill Cool Contents
Oxygen

Combustion Triangle Pulverized Fuel In Suspension

Ignition Source

Pulverizer Operational Safety

Dust Suppression System

General Information Developed and Patented by Westerns Farmers Electric Coop. (WFEC) WFEC System Utilizes Water Fog, Water Swirl, and CO2 ALSTOM Power Has License Agreement With WFEC WFEC Has Sold Licenses to Individual Plants ALSTOM Experience Via. Western Farmers Electric Coop. ALSTOM Has Been Working With WFEC For Over 3 Years ALSTOM Optimized First System Fall 2001

Pulverizer Operational Safety

Dust Suppression System
Principle Of Operation - Inerting vs. Dust Suppression Pulverizer Explosions Require

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

Steam Inerting Systems:

Dust Suppression Systems:

Pulverizer Operational Safety

Dust Suppression System Schematic

Pulverizer Operational Safety

Dust Suppression System Water Fog
Injected At:

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

Automatically Activated Upon Detection of Hazardous Condition

Can Be Manually Activated (Normal Starts and Stops) Water Nozzles Kept Clean With Seal Air During Normal Mill Operation

Pulverizer Operational Safety

Dust Suppression System Water Swirl
Safely Empties Contents Pulverizer To Pyrite System Introduces Through (8) Nozzles Under Bowl Approx. 7 GPM/Nozzle Used With Bowl Rotating Manually Activated - Operator Visually Insures Mill is Empty by Inspecting Pyrite Discharge Water Nozzles Kept Clean With Seal Air During Normal Mill Operation