Fuel and Air Gas Circuit

Suction Mill Air Supply System

Oil Pumping, Heating and Recirculation System

Oil is ignited by expelling the oil through a small nozzle ( a pressure jet) or by compressed air or steam, this process is called atomization. The fuel is circulated to the burners via a recirculation system, this process is referred to as spill-back.

Gas-firing systems

Protection against leakage into the furnace through the fuel-supply valves is achieved by use of double-block-and-bleed valve assemblies which provide a secure seal between the gas inlet and the furnace. Before a burner is ignited both block valves are closed and the vent is opened. In this condition any gas which may occupy the volume betwwen the two block valves is vented to a safe placeand it can never develop enough pressure to leak past the second block valve. When start-up of the burner is required, a sequence of operations opens the block valves in such a way thet gas is admitted to the burner and ignited safely.

Waste to Energy Plant based on Bubbling Fluidized Bed Boiler

Burner Management System

Safe operation of burner and igniters Flame Scanner Sequential operation of fuel firing system (safe start up, shut down) Purging done for a stipulated time by the FD & ID Fans ensuring that a certain volume of clear ambient air (In a coal fired boiler the flow rate > 40% of the full-load volumetric air flow) has passed through the furnace.

Boiler firing is initiated, ignition is successful operation of igniter or pilot Flame scanners (ensure presence of flame inside furnace): electronic devices operating in close proximity to high-energy spark ignition systems, and in conditions of extreme heat and dirt. The should provide reliable indication of flame. Flame failure trip a protection against accumulation of unburnt fuel which could lead to explosion On shut-down of a burner, unburned fuel is cleared from the pipework by a procedure called scavaging.

Oil Pumping, Heating and Recirculation System

Control System Includes Controlling the temperature of the fuel The pressure of the atomizing medium The equalization of the fuel pressure at various levels on the burner front

Combustion Control

Heat Losses in a Furnace

These are, Heat wasted in the exhaust gases Heat content of the fuel which is due to unburnt carbon Heat lost by radiation from hot surfaces in the boiler and its pipework

Heat Losses in a Furnace

Tramp Air or Setting Leakage

Air is not evenly distributed within the furnace. For example, operational considerations require that a supply of cooling air is provided for idle burners and flame monitors, to prevent them being damaged by heat from nearby active burners and by general radiation from the furnace. Air also enters the combustion chamber through leaks, observation ports, soot-blower entry points and so on. The sum of all these is referred to as tramp air or setting leakage.

Effect of Tramp Air or Setting Leakage

If the tramp air or setting leakage amount is included in the total air being supplied to the furnace, and if that total is apportioned to the total amount of fuel being fired, the implication is that some burners (at least) will be deprived of the air they need for combustion of their fuel. In other words, the correct amount of air is being provided in total, but it is going to places where it is not available for the combustion process.

Simple Parallel Control

The easiest way of maintaining a relationship between fuel flow and air flow is to use a single actuator to position a fuel-control valve and air-control damper in parallel with each other.

Limitations of Simple Parallel Control

Its applicable only for smaller boilers The amount of fuel or air flow through a valve is not constant and varies with pressure for a particular opening The response time of fuel flow controller is different from the air flow controller. Thus the ratio may not be desirable during transit time.

Flow Ratio Control

Its a closed loop controller with measured value of fuel and air flow linked to controllers for tracking each other. A gain block or amplifier in one of the flow-signal lines is used to adjust the ratio between the two flows. As the gain of this block is changed, it alters the slope of the fuel-flow / air-flow characteristic, changing the amount of excess air that is present at each flow.

Flow Ratio Control

As the gain (g) of the block is changed, it alters the slope of fuel-flow / air-flow characteristic, changing the amount of excess air that is present in each flow. When the gain is fixed , the amount of excess air is the same for all flows. However some air inevitably leaks into the furnace, with the result that the amount of excess air is proportionally greater at low flows than high flows.

Flow Ratio Control

The excess air line curves hyperbolically upwards at low flows. Practically the air flow is slightly greater than the theoretical air as per the stoichiometric ratio.

Flow Ratio Control

In a fuel lead system , when the load demand changes, the fuel flow is adjusted first and the controller than adjusts the air flow to match the fuel flow. In air lead system , when the load demand changes, the air flow is adjusted first and the controller than adjusts the fuel flow to match the air flow.

Comparing the fuel-lead and airlead approaches

Fuel-lead version provides better response to load changes, as it does not depend on the slow response air supply system. The air lead system is slow as the draught plant is slow to react. This can lead to fuel rich conditions on load increases and fuel lean conditions on load decrease. Fuel-rich condition can cause explosion. Too much excess air can lead to back-end corrosion of boiler structure and undesirable stack emissions. Hazard in air-lead system is slow as the load increases. As the load decreases however the slow responding air system is prone to create fuel reach conditions, however the hazard is lesser. The failure of air flow measurement transmitters also is risky.

Basic Cross Limited Control System

FUEL FLOW MASTER DEMAND AIR FLOW

FUEL VALVE

AIR CONTROL VALVE

GAS ANALYSIS FOR FUEL/ AIR RATIO

OXYGEN TRIMMING OF FUEL- AIR RATIO

GAS ANALYSIS FOR FUEL/ AIR RATIO

OXYGEN TRIMMING OF FUEL- AIR RATIO The oxygen content of air is 21% by volume. A given change in oxygen represents approximately five times that change in excess air. It is the air flow being controlled. The gain of the controller should be set at a kick-off low value(0.25) and a proportional band of 400%. The time constants of the fuel/air/flue-gas system are long, hence the integral term of oxygen controller tends to be long.

 The set value of oxygen controller is trimmed by the output of the carbon monoxide controller.

Carbon in ash measurement

Multiple Burner System

Oil and gas burners can be operated by maintaining a defined relationship between the fuel pressure and the differential pressure pressure across the burner air register (rather than proper flow measurements), but even with such economics the capital costs are high and the payback low. The need to provide a modulating actuator for each air register adds further cost.

Setting the demand for the steam generator

Nature of the demand

Steam is generated in boiler by burning fuel. Boiler Fuel Master demand is set as per the steam demand BFM sets the burner firing rate, air flow, feed water flow