Sei sulla pagina 1di 92

Coal And Ash Handling

Systems

Faculty Name: P.THARUN SAI


Branch: Mechanical
College : LBRCE
Semester: 8th Semester
Name of Subject: Power Plant Engineering
Outline
• Introduction
• Coal handling
• Coal storage
• Burning systems
• Types of stokers and their working
• Pulverized fuel handling systems
• Pulverized mills
• Pulverized coal burners
• Oil burners
• Ash Handling Plant
• Dust collection and its disposal
Ajaypalsinh Barad 2
Concept:

Ajaypalsinh Barad 3
Concept:

Ajaypalsinh Barad 4
Concept:

Ajaypalsinh Barad 5
Concept:

Ajaypalsinh Barad 6
Concept:

Ajaypalsinh Barad 7
Coal Handling :
• Coal delivery:
• Unloading
• Preparation of coal
• Transfer of coal
• Storage of coal
• Inplant handling
• Weighing of coal
• Magnetic separators
• Crushers

Ajaypalsinh Barad 8
Requirement of good coal handling :

• It should have minimum maintenance.


• It should be simple
• It should be reliable
• It should supply coal continuously as per the demand
of power plant.
• It should have minimum wear in running the
equipment.

Ajaypalsinh Barad 9
Coal storage:
• To store the coal for a period of 30 to 90 days.
• To permit the choice of the date of purchase.
• Coal is stored in the form of heaps up to a height of 10
to 12 m directly on concrete ground.
• The pile top should be given a gentle slope in which
the rain may be drained off.

Ajaypalsinh Barad 10
Coal storage:
Under water storage:
• The possibility of slow oxidation and spontaneous
combustion can be completely eliminated by storing
the coal under water.
Live storage or active storage:
• The coal is usually stored in vertical cylinder bunkers
or coal bins.
• Live coal storage bunkers are normally constructed
with a diamond-shaped cross section storage area.
• The storage bunkers are made of steel or reinforced
concrete to store the live coal.
Ajaypalsinh Barad 11
Coal storage:

Ajaypalsinh Barad 12
Burning systems:
• Fuel is burnt in a confined space known as furnace.
The furnace provides support and enclosure for
burning equipment.
• Solid fuels such as coal, wood are burnt by means of
stockers whereas burners are used to burn pulverized
coal and liquid fuels.
• Solid fuels require a grate in the furnace to hold the
bed of fuel.

Ajaypalsinh Barad 13
Selection of fuel firing methods:
• The characteristics of the available coal
• Capacity of the plant
• Efficient operation of the system.
• Reliability of the equipments
• Nature of load fluctuation.
• Cost of equipment and maintenance.

Ajaypalsinh Barad 14
Solid fuel firing :
Hand firing system:
• It is simple and suitable for small power plant. Since
it is difficult to achieve the uniform combustion and it
gives low combustion efficiency.
Stoker firing:
• Stoker is a power operated fuel feeding mechanism
and grate. With stoker firing , it allows to burn large
quantities of fuel, with easy in controlling the
combustion with higher efficiency, less labor of
handling ash and are self cleaning.

Ajaypalsinh Barad 15
Advantages of stoker firing :
• Ease of control of combustion
• High combustion efficiency
• Cheaper grade of fuel can be used
• Smokeless combustion
• Less labor required
• System is reliable

Ajaypalsinh Barad 16
Disadvantages of stoker firing:
• Capital cost is high
• Loss of coal through the grates
• Steam demand due to load fluctuations on plant can
not be met efficiently
• Complicated construction and arrangement
• Excessive wear of parts

Ajaypalsinh Barad 17
Stokers:
• A grate is used at furnace bottom to hold a bed of fuel.
• There are two ways of feeding coal on to the grate
– Over feeding
– Under feeding
• Therefore automatic stockers may be classified as
overfeed and under feed stockers.

Ajaypalsinh Barad 18
Principles of Overfeed Stokers :
• It receives the coal on its top surface and is
characterized by the following five zones from top to
the bottom.
• A layer of fresh or green coal - Fresh CoalZone
• A layer of coal losing moisture - Drying Zone
• A cooking layer of coal losing its volatile content -
Distillation Zone.
• A layer of incandescent coke where the fixed carbon is
consumed - Combustion Zone
• A layer of ash progressively getting cooler - Ash
Zone.
Ajaypalsinh Barad 19
Principles of overfeed stokers :

Ajaypalsinh Barad 20
Principles of overfeed stokers :
• Pressurized air --- FD Fan --- Bottom of the grate ---
Heated by absorbing heat from ash and grate --- Ash
and grate are cooled --- Hot air --- Incandescent
coke --- O2 reacts with C --- CO2 --- Hot gases ---
Distillation zone --- Volatile matter added --- Drying
zone --- Moisture is picked up --- Finally come out
from the bed containing N2, CO2, CO, H2 ---
Secondary air supplied --- High speed ---
Turbulence --- complete combustion.

Ajaypalsinh Barad 21
Types of overfeed stoker :
It may be classified as
• Travelling grate stoker
• Spreader stoker

Ajaypalsinh Barad 22
Travelling grate stoker :

Ajaypalsinh Barad 23
Travelling grate stoker :

Ajaypalsinh Barad 24
Travelling grate stoker :
Advantages:
• Simple in construction
• Maintenance cost is low
• Initial cost is low.
• Self cleaning stoker
• Heat release rate can be controlled just by controlling
the speed of chain.
• Ash crushers are not required.

Ajaypalsinh Barad 25
Travelling grate stoker :
Disadvantages:
• Always some loss of coal in the form of fine particles
carried with the ashes.
• Temperature of preheated air is limited to 180°C.
• Not suitable for high capacity boiler
• Clinker trouble are very common.

Ajaypalsinh Barad 26
Spreader stoker :

Ajaypalsinh Barad 27
Spreader stoker :

Ajaypalsinh Barad 28
Spreader stoker :
Advantages:
• A wide variety of coal can be burnteasily
• It can respond quickly with load changes as it has a
small depth of furnace bed on grate.
• Operation cost is low
• Use of high temperature preheated air is possible.
• Clinkering difficulties are reduced.

Ajaypalsinh Barad 29
Spreader stoker :
Disadvantages:
• Work satisfactory with 40 mm or small size of coal.
• Fly ash is more, dust collector is needed.
• Clinker problem can not be avoided.

Ajaypalsinh Barad 30
Principle of underfeed stokers :

Ajaypalsinh Barad 31
Types of Underfeed Stokers :
• Single retort underfeed stokers.
• Multi retort underfeed stokers.

Ajaypalsinh Barad 32
Single retort stoker :

Ajaypalsinh Barad 33
Single retort stoker :

Ajaypalsinh Barad 34
Multi retort stoker :

Ajaypalsinh Barad 35
Underfeed stoker :
Advantages:
• Coal can be used directly from mines.
• High combustion efficiency.
• Can be used for medium sized plants.
• Space requirement is less
• Variation in load can be met easily.
• Dust collection problem is less.

Ajaypalsinh Barad 36
Underfeed stoker :
Disadvantages:
• Initial cost high
• Wear and tear is high
• Low grade fuels can not be burnt efficiently
• Clinker formation can not avoided.
• Loss of coal take place.

Ajaypalsinh Barad 37
Pulverized Coal System :

Ajaypalsinh Barad 38
Pulverized Coal System :
Advantages:
• Any type of coal can be used.
• Complete combustion is possible.
• Reduces air requirement, grater surface area.
• Fast response to variation in load.
• No clinker formation.
• No moving parts in furnace, Life of system is high.
• No ash handling problem.
• Less furnace volume required.

Ajaypalsinh Barad 39
Pulverized Coal System :
Disadvantages:
• High capital cost
• High operation cost
• Special equipments required to remove fly ash
• Due to high furnace temperature needs cooling
arrangement.
• Maintenance cost is high
• Skilled labor needed
• High air pollution
• Necessity of special starting equipment.
Ajaypalsinh Barad 40
Pulverized Fuel Handling System :
• It is further divided into two types:
– Unit System
– Central System

Ajaypalsinh Barad 41
Unit System :

Ajaypalsinh Barad 42
Unit System :
Advantages:
• Simple and cheaper than central system
• Operation and transportation is simple
• Direct control of combustion
• Maintenance charges are less

Ajaypalsinh Barad 43
Unit System :
Disadvantage:
• Poor performance due to variable load on plant
• Degree of flexibility is less
• Exhaust fan is subjected to excessive wear as it
handles dust particles also.

Ajaypalsinh Barad 44
Central (Bin) System :

Ajaypalsinh Barad 45
Central System :
Advantages:
• Continuously coal supply possible due to reserve coal.
• Pulverizing mill grinds coal at steady rate
• Less operators are needed.
• Power consumption per ton of coal crushed is less.
• Coal and air supply is controlled separately
• No wear and tear of fan since it handles only air

Ajaypalsinh Barad 46
Central System :
Disadvantages:
• Initial cost is high
• Coal transport system is complicated
• System requires more space
• Operation and maintenance cost is higher.

Ajaypalsinh Barad 47
Pulverized mills:
• Pulverizing mills called Pulverizer, which are used
to convert the crushed coal particle into fine dust
particle.
• It is of following types:
– Attrition Mills
• Ball and Race Mill
• Bowl Mill
– Impact Mills
• Ball Mill
• Hammer Mill

Ajaypalsinh Barad 48
Ball & race mill:

Ajaypalsinh Barad 49
Bowl mill:

Ajaypalsinh Barad 50
Ball Mill:

Ajaypalsinh Barad 51
Ball Mill:

Ajaypalsinh Barad 52
Impact or hammer mill:

Ajaypalsinh Barad 53
Pulverized coal burners:
Requirements of pulverized coal burners :
• Stable ignition
• It should thoroughly mix the coal and primary air.
• Ensure complete combustion.
• Control flame size and shape.
• Protection against overheating and excessive power.

Ajaypalsinh Barad 54
Pulverized coal burners:
Factors affect the performance of Pulverized Burner:
• Characteristics of coal used
• Grain size of powder coal.
• Quantity of volatile matter in coal.
• Geometry of coal burners.
• Quantity of primary and secondary air used.
• Furnace design.
• Load on plant.
• Method of mixing of coal and primary air.

Ajaypalsinh Barad 55
Classification of pulverized coal burners :
• Vertical long flame burner
• Turbulent (short) flame burner
• Tangential burner
• Cyclone burner

Ajaypalsinh Barad 56
Vertical Long Flame Burner:
• It is also known as
U-flame or Stream
lined burners.

Ajaypalsinh Barad 57
Turbulent (Short) Flame burners :

Ajaypalsinh Barad 58
Tangential burners:
• Flame produced by the burners at four corners is tangential
to the imaginary circle at the centre.
• It produced high degree of turbulence at the centre.

Ajaypalsinh Barad 59
Tangential burners:
Advantages :
• Simple operation
• High rate of energy release
• Complete combustion
• No additional turbulence
• Can be used with liquid, gaseous and pulverized coal

Ajaypalsinh Barad 60
Cyclone Burners:
• To avoid cost of pulverization crushed coal can be used in
cyclone burner instead of pulverized coal.

Ajaypalsinh Barad 61
Cyclone Burners:
Advantages:
• Simple coal crushing equipment can be used
• Operation cost reduce
• Can burn low grade fuels
• Rate of combustion can be controlled by adjusting the rate
of fuel and air flow.
Disadvantages :
• High power required for fan
• NOx emissions are high.

Ajaypalsinh Barad 62
Oil burners:
• Required to be used for small capacity boilers.
• Purpose :
– To receive supply of oil
– Meter it according to load
– Atomize and vaporize completely
• Classification :
– Vaporizing burner
– Atomizing burner

Ajaypalsinh Barad 63
Oil burners:
• Vaporizing burner:
– Used for domestic and industrial application
– Not used for steam generation in boilers
• Atomizing burner:
– To atomize the fuel into fine particles and mix with air.
– Used for oil fired furnaces in boiler
– High pressure air burner
– Mechanical burner

Ajaypalsinh Barad 64
Oil burners:
High pressure air burner:
• Also known as steam atomizing burner and Blast
atomization.
• The high velocity of steam or air divides the oil into very
fine particles which are sprayed into the furnace.

Ajaypalsinh Barad 65
Oil burners:
Mechanical burner:
• Further classified as:
– Spray nozzle
• The oil is injected under high pressure and high
temperature through small nozzle. The oil leaves the
nozzle in atomized form.
– Rotary burner
• The oil is passed under pressure into conical chamber due
to centrifugal action the oil leaves the orifice in the form
of a hollow cone of fine particles.

Ajaypalsinh Barad 66
Oil burners:
Mechanical burner:

Ajaypalsinh Barad 67
Necessity of Ash Disposal :
• Irritating and annoying to handle to eyes.
• Forms clinkers by fusing
• At outlet ash is hot so quenching is necessary
• It will wear the conveyor parts in contact with it in
case of relative motion
• Produces corrosive acids when mixed with water.

Ajaypalsinh Barad 68
Ash Handling System :
A good ash handling system shouldhave:
• Large quantity of ash should be removed at high rate
• Load the ash collected on conveyor system
• Deliver the ash from conveyor to ash storage
• Disposal of stored ash
• Equipments should be corrosion and wear resistant
• Plant should be noiseless
• Equipment should be able to handle clinkers, dust etc
smoothly.
• Capital investment, operating and maintenance cost
should be low.
Ajaypalsinh Barad 69
Ash Handling System :

Ajaypalsinh Barad 70
Ash Handling System :
Types of ash handling system :
• Hydraulic ash handling system
– Low velocity
– High velocity
• Pneumatic ash handling system
• Mechanical ash handling system

Ajaypalsinh Barad 71
Hydraulic Ash Handling System :
Low velocity Hydraulic system:

Ajaypalsinh Barad 72
Hydraulic Ash Handling System :
High velocity Hydraulic system:

Ajaypalsinh Barad 73
Hydraulic Ash Handling System :
Advantages :
• High capacity, more suitable for super plants
• Clean and dust free operation
• Handle molten ash
• No working parts in contact with ash so minimum
erosion problem
Disadvantages :
• In contact with water ash forms corrosive acids
• Water channel and pump must be made of wear resisting
material.

Ajaypalsinh Barad 74
Pneumatic Ash Handling System :

Ajaypalsinh Barad 75
Pneumatic Ash Handling System :
Advantages :
• Dust free operation
• No rehandling trouble
• Dry ash handling eliminates chances of ash freezing,
sticking in the storage bin
• Less installation cost per ton of ash handled
Disadvantages :
• Noisy in operation
• High maintenance due to wearing of pipelines by ash

Ajaypalsinh Barad 76
Mechanical Ash Handling System :

Ajaypalsinh Barad 77
Mechanical Ash Handling System :
Advantages :
• Low power consumption
• Continuous ash removal
Disadvantages :
• Suitable for low capacity plants
• Life span is about 5 to 10 years

Ajaypalsinh Barad 78
Dust Collection and Disposal:
Requirements for a good dust collector :
• Able to remove fine particles
• Low operation and maintenance cost
• Low capital cost
• Resistant to erosion by fly ash
• Occupy minimum floor space
• Operate at high efficiency at all loads

Ajaypalsinh Barad 79
Dust Collection and Disposal:
• In coal fired boilers the flue gases have certain
particles of solid matter, called Smoke or Dust.
• Particle size 1 to 100 microns - Dust
•Particle size more than 100 microns – Cinder
Types of dust collector:
– Mechanical dust collector
– Electrostatic dust collector

Ajaypalsinh Barad 80
Mechanical Dust Collector:
• Dry type Dust Collector
– Gravitational Separator
– Cyclone Separator
• Wet type Dust Collector
– Spray Type Scrubber
– Packed Bed Scrubber

Ajaypalsinh Barad 81
Mechanical Dust Collector:
Gravitational Dust Collector

Ajaypalsinh Barad 82
Mechanical Dust Collector:
Gravitational Dust Collector :
Advantages :
• Simple arrangement
• Less capital and operating cost
Disadvantages :
• Only large size and heavy particles can be removed
• Bulky and requires large space

Ajaypalsinh Barad 83
Mechanical Dust Collector:
Cyclone Separator :
• Laden gas is made to flow
in the inner vortex
upwards.
• Performance depends on
volume of gas handled, gas
characteristic, inlet velocity
and size of chamber.

Ajaypalsinh Barad 84
Mechanical Dust Collector:
Cyclone Separator :
Advantages :
• High efficient for bigger particles
• Low maintenance cost
• Simple, cheap and easy to operate
• With increasing load, efficiency increases
Disadvantages :
• Require more power to produce high vortex
• Require more space
• With increasing fine particles, efficiency declines
Ajaypalsinh Barad 85
Mechanical Dust Collector:
Wet type Dust Collector :
• Not suitable for large power
plant
• Chemical neutralization
needed before polluted
water discharged

Ajaypalsinh Barad 86
Electrostatic Precipitator:

Ajaypalsinh Barad 87
Electrostatic Precipitator:

Ajaypalsinh Barad 88
Electrostatic Precipitator:

Ajaypalsinh Barad 89
Electrostatic Precipitator:

Ajaypalsinh Barad 90
Electrostatic Precipitator:
Advantages :
• Fine dust particles can be removed efficiently
• Low maintenance
• Easy to operate
• Dust is collected in dry form
Disadvantage :
• High capital cost
• High operational charge
• Space requirement is high
• With increase in gas velocity dust collection efficiency
reduced.
Ajaypalsinh Barad 91
Ajaypalsinh Barad 92

Potrebbero piacerti anche