Bharat Heavy Electricals Limited, Tiruchirapalli Bharat Heavy Electricals Limited, Tiruchirapalli

Bharat Heavy Electricals Limited,

Tiruchirapalli
Power Plant Summit 2008 – Optimised Design for Low Grade Indian Coals Bharat
Power Plant Summit Heavy Electricals
2008 – Optimised DesignLimited, Tiruchirapalli
for Low Grade Indian Coals

Bharat Heavy Electricals Limited, Tiruchirapalli Bharat Heavy Electricals Limited, Tiruchirapalli
BHEL Utility Units - A Summary
Unit Rating Contracted Commissioned
MW No. MW No. MW
BHEL’
BHEL’s Contribution To Power Sector 30 4 120 4 120

(As on 31.03.2008) 60 16 960 16 960

67.5 9 608 8 540

India’
India’s installed capacity 134697 MW 70 10 700 9 630
80 12 960 3 240

BHEL-
BHEL-built sets account for 85786 MW 100 6 600 6 600
110 39 4290 39 4290

(64% of India’
India’s installed capacity) 120 31 3720 27 3240
125 6 750 - -

PLF 130 2 260 2 260

200 20 4000 20 4000

National average 77.9% 210 114 23940 108 22680

270 2 540 - -

BHEL Thermal Sets 79.9% 250 50 12500 16 4000

500 71 35500 31 15500

BHEL’
BHEL’s 200/210/250/500MW Sets 85% 600 1 600 - -
660 2 1320
800 2 1600 - -
TOTAL 397 92968 289 57060

Power Plant Summit 2008 – Optimised Design for Low Grade Indian Coals Power Plant Summit 2008 – Optimised Design for Low Grade Indian Coals
 Bharat Heavy Electricals Limited, Tiruchirapalli

BHEL Industrial Units - A Summary BSES - 250 MW

73200
Bombay Sub-urban
Unit Contracted Commissioned CUSTOMER Electric Supply
Corporation
VU 40 46 44
58606 Parameters at SHO
VU 40 S 15 15 Steam flow t/h 805

REHEATER
VU 60 26 19 Pressure Kg/Sq.cm(g) 155

FINISHSH
PLATENSH
MU 3 3 Temperature Deg.C 540
LTSH

VP 22 16 ECONOMISER
FUEL Coal / Natural Gas
FURNACE ECONOMISER

V2R 17 16 (Future)
DATE OF
HRSG 131 112 COAL January 1995
BUNKER COMMISSIONING
AFBC 66 58 WINDBOX

16000
SALIENT FEATURES Single Drum
CFBC 18 5 AIRHEATER
Two Pass
Others 28 28
9000
Natural Circulation
Total 372 316 PA FAN
TUBE
MILL Balanced Draft
0000
FDFAN
Tilting Tangential Firing

Power Plant Summit 2008 – Optimised Design for Low Grade Indian Coals

500 MW NTPC SINGRAULI 6

Supercritical
Separators

Collecting Steam Generators

vessel
 Bharat Heavy Electricals Limited, Tiruchirapalli Bharat Heavy Electricals Limited, Tiruchirapalli

COAL CLASSIFICATION
A TYPICAL INDIAN CLASSIFICATION
THE CLASSIFICATION OF COALS AS PER
INTERNATIONAL PRACTICE THE SINGARENI COLLIERIES CO. LTD ( SCCL )

ü ANTHRACITE, BITUMINONS, SUB-

SUB-BITUMINONS, UHV AND GCV RANGES FOR DIFERENT GRADES OF NON-
NON-
LINITE ETC.
COKING COALS

ü HARD COALS, BROWN COALS &

LIGNITE Where A = Ash % and M = Moisture % determined at 60% RH and 40 oC

ü ON THE BASIS OF VOLATILE OF THE THIS COALS MOSTLY D,E &F GRADE COALS ARE ONLY
MATTER CONTENT CONTEMPLATED FOR BOILER APPLICATION

ü ON THE BASIS OF CALORIFIC

VALUE

Power Plant Summit 2008 – Optimised Design for Low Grade Indian Coals Power Plant Summit 2008 – Optimised Design for Low Grade Indian Coals

Bharat Heavy Electricals Limited, Tiruchirapalli Bharat Heavy Electricals Limited, Tiruchirapalli

SCCL GRADES OF COALS

Ø Coals vary widely in their properties

Ash %+
GCV at 5% Moisture GRADE UHV
Moist % - mine to mine and seam to seam
6400 A 6200 19.60

5800 B 5600 23.90

5400 C 4940 28.70 ØCoal firing therefore presents a

4800 D 4200 34.10 varying set of demands before the
4200 E 3360 40.10 boiler designer
3600 F 2400 47.10
3200 G 1300 55.10

Power Plant Summit 2008 – Optimised Design for Low Grade Indian Coals Power Plant Summit 2008 – Optimised Design for Low Grade Indian Coals
 Bharat Heavy Electricals Limited, Tiruchirapalli Bharat Heavy Electricals Limited, Tiruchirapalli

Coal Analysis -Typical Indian Coals

Normally specified Coal Properties
Proximate Analysis
þ Proximate Analysis Unit Design Worst Best
Coal Coal Coal
þ Ultimate Analysis
þ Calorific Value
Fixed carbon % 22.0 20.0 25.0
þ Ash Constituents
Volatile matter % 21.0 19.5 23.0
þ Ash Fusion Temperatures Moisture % 15.0 16.5 14.0
þ Hard Grove Index Ash % 42.0 44.0 38.0
Total % 100.0 100.0 100.0
þ YGP Index
HHV Kcal/kg 3300 3000 3600

Power Plant Summit 2008 – Optimised Design for Low Grade Indian Coals Power Plant Summit 2008 – Optimised Design for Low Grade Indian Coals

Bharat Heavy Electricals Limited, Tiruchirapalli Bharat Heavy Electricals Limited, Tiruchirapalli

Coal Analysis -Typical Indian Coals

Ultimate Analysis
PROBLEMS ASSOCIATED WITH INDIAN COALS
Unit Design Coal Worst Coal Best Coal

Carbon % 33.73 30.90 38.26 INCONSISTENT COAL PROPERTIES

Hydrogen % 2.35 2.09 2.49 PRESENCE OF EXTRANEOUS MATTERS IN COAL
Oxygen(difference) % 5.48 5.00 5.96 HIGH QUANTUM OF ASH WITH HIGH PERCENTAGE OF
sulphur % 0.37 0.36 0.38 QUARTZ
Nitrogen % 0.75 0.85 0.57 HIGHLY ABBRASIVE NATURE OF COAL ASH
Moisture % 15.00 16.50 14.00 DUE TO LOW SULPHUR CONTENT- EXTREMLY HIGH
Ash % 42.00 44.00 38.00 ELECTRICAL RESISTIVITY OF ASH
HARD GROVE INDEX 55 54 56 LOW HEATING VALUE OF THE COAL

Power Plant Summit 2008 – Optimised Design for Low Grade Indian Coals Power Plant Summit 2008 – Optimised Design for Low Grade Indian Coals
 Bharat Heavy Electricals Limited, Tiruchirapalli Bharat Heavy Electricals Limited, Tiruchirapalli

Ash Characteristics -Typical Indian Coals

Design Worst Best Ash Analysis
Initial Deformation Temp. Deg.C 1150 1100 1200
Provides indicators to
Hemispherical Temp. Deg.C 1400 1400 1400
Fusion Temp. Deg.C 1400 1400 1400 F Slagging / fouling / deposition potential
Ash Analysis:
F Erosion potential
A – SiO 2 % 60.08 61.40 60.30
A – Al2O3 % 29.50 28.50 29.80 F Corrosion potential
B – Fe2O3 % 4.10 3.90 4.70
B – CaO % 1.70 1.93 1.57
B – MgO % 0.75 0.92 0.59
B – Na2O + K2O % 0.65 0.85 0.53
A – TiO 2 % 1.70 1.60 1.80
- P 2O5 % 0.80 1.10 0.13
- SO3 % 0.27 0.31 0.25

Power Plant Summit 2008 – Optimised Design for Low Grade Indian Coals Power Plant Summit 2008 – Optimised Design for Low Grade Indian Coals

Bharat Heavy Electricals Limited, Tiruchirapalli Bharat Heavy Electricals Limited, Tiruchirapalli

Slagging/deposition indices COAL PROPERTIES INFLUENCING BOILER DESIGN

• Ash deformation temperatures

Lower the number, higher the tendency for deposition
• Base/ Acid Ratio
In certain ranges the combinations have low melting
temperatures, resulting in higher deposition
• Iron/ Calcium ratio
lower fusiblity temperatures in certain ranges
• Iron Content in Ash
Higher the content , more the propensity for deposition
• Silica / Alumina Ratio
Lower fusiblity temperatures at higher ratios
• Viscosity Index

Power Plant Summit 2008 – Optimised Design for Low Grade Indian Coals Power Plant Summit 2008 – Optimised Design for Low Grade Indian Coals
 Bharat Heavy Electricals Limited, Tiruchirapalli Bharat Heavy Electricals Limited, Tiruchirapalli

COAL PROPERTIES INFLUENCING BOILER DESIGN COAL PROPERTIES INFLUENCING BOILER DESIGN

Power Plant Summit 2008 – Optimised Design for Low Grade Indian Coals Power Plant Summit 2008 – Optimised Design for Low Grade Indian Coals

Bharat Heavy Electricals Limited, Tiruchirapalli Bharat Heavy Electricals Limited, Tiruchirapalli

DESIGN CONSIDERATIONS FOR LOW GRADE INDIAN COAL Comparison of Furnace

Low Grade Indian coal Vs International Coal – 500 MW
I. FURNACE :
CONSERVATIVE FURNACE HEAT LOADINGS – Liberal loading –
Large furnace
HIGHER RESIDENCE TIME ( Around 1.5 – 2 second )
NOMINAL FURNACE OUTLET TEMPERATURE
NOMINAL FLUE GAS TEMPERATURE Entering the Heat transfer
Sections. – ( Less than ash softening Temperature )
MORE NUMBER OF WALL DESLAGGERS

Power Plant Summit 2008 – Optimised Design for low Grade Indian Coals Power Plant Summit 2008 – Optimised Design for Low Grade Indian Coals
 Bharat Heavy Electricals Limited, Tiruchirapalli Bharat Heavy Electricals Limited, Tiruchirapalli

DESIGN CONSIDERATIONS FOR LOW GRADE INDIAN COAL DESIGN CONSIDERATIONS LOW GRADE INDIAN COAL

II. DESIGNING FOR EROSION PROTECTION III. FUEL PIPE BENDS

• Indian coals contain large quantum of ash CERAMIC LINED FUEL PIPE BENDS

The quantity of ash passing thru the boiler is of the order of 125 OPTIMUM VELOCITY ( around 30 m/s )
kg/ Million kcal (compared to 40 kg/Mkcal for an average grade
coal) HIGHER THICKNESS PIPES ( 12.7 mm )
• Indian coal-ash highly erosive- 60% Silica. IV. AIR HEATERS
• Flue gas velocity in the range of 10-12 m/s REVERSE ROTATION OF AH, HIGHER SIZE TO DRY HIGH
adopted MOISTURE.
• Additional thickness provided on tubes in erosion EXTENDED TUBE-TUBULAR APH
prone areas
DOUBLE SEAL ARRANGEMENT
• Sacrificial shields/ baffles provided on leading
tubes/ bends SINGLE ROUGHED ROTOR POST

Power plant summit 2008 – Optimised design for low grade indian coals Power plant summit 2008 – Optimised design for low grade indian coals

Bharat Heavy Electricals Limited, Tiruchirapalli Bharat Heavy Electricals Limited, Tiruchirapalli

DESIGN CONSIDERATIONS LOW GRADE INDIAN COAL DESIGN CONSIDERATIONS LOW GRADE INDIAN COAL
VII. ID FANS
LOW SPEED
V. PULVERISER :
TO SIZE for WORST COAL & LEAKAGES
SPARE CAPACITY ( No. of working Mills +1 or 2 )
WEAR LINED IMPELLERS BLADES
ABRASSIVE RESISTANCE MATERIALS ( Weld overlay, Nihard )
HIGHER VOLUME (20%) AND HEAD(30%) AND
MORE VOLUME FOR COAL MOISTURE DRYING ( Tall Top
TEMPERATURE MARGINS ( PLUS 10 Deg.C)
Classifier)
WITHDRAWAL GEAR BOX VIII. PA FANS.
SPACIOUS LAYOUT HIGHER CAPACITY
HIGHER MARGINS ON VOLUME (20%) AND HEAD(30%),
VI. BURNERS
TO SIZE for WORST COAL, SPARE MILLS & LEAKAGES
SPLIT COAL NOZZLE
WIDE RANGE COAL NOZZLES

Power plant summit 2008 – Optimised design for low grade indian coals Power plant summit 2008 – Optimised design for low grade indian coals
 Bharat Heavy Electricals Limited, Tiruchirapalli Bharat Heavy Electricals Limited, Tiruchirapalli

DESIGN CONSIDERATIONS LOW GRADE INDIAN COAL DESIGN CONSIDERATIONS LOW GRADE INDIAN COAL
IX. ESP
BIGGER ESP
IX. BOILER LAYOUT
LOW FLUE GAS VELOCITY
REAR MILL LAYOUTS
HIGHER EFFICIENCY
HIGHER SCA

X. DUCTING
LESSER FLUE GAS VELOCITY (15 m/s upto ESP and 20 m/s After ESP )
PROPER METALLURGY TO AVOID WEAR IN DAMPERS & GATES
PROPER LAYOUT TO AVOID ASH ACCUMULATION
Ash Handling system design & Operation to evacuate the ash on
time & to avoid build up.

Power Plant Summit 2008 – Optimised Design for Low Grade Indian Coals Power Plant Summit 2008 – Optimised Design for low Grade Indian Coals

Bharat Heavy Electricals Limited, Tiruchirapalli Bharat Heavy Electricals Limited, Tiruchirapalli

FEED BACK AND DESIGN IMPROVEMENTS

BHEL’
BHEL’s EXPERIENCE WITH INDIAN COALS ØBHEL UPDATES THE DESIGN CONTINUOUSLY BY
SYSTEMATIC COLLECTION OF DATA FROM OPERATING UNITS.

• Unique experience of having designed and installed more

than 290 coal-
coal-fired Utility Steam Generators ranging from
60MW to 500MW (58000 MW) firing low calorific value/high
ØWHEN FIRST GENERATION 210 MW UNITS WAS INTRODUCED
FIRST TIME IN THE COUNTRY IN 1970’
1970 ’s, A HIGH AMBITIOUS
ash/ erosive Indian coals.
STABILIZATION PROGRAM WAS CARRIED OUT TO IMPROVE
• Boiler design is continuously updated by BHEL OPERATING AVAILABILITY AND PLF.
incorporating the state of art improvements and feedbacks
gained from operating Units.
ØTHE OPERATING FEED BACK COLLECTED FROM THESE HIGH
ASH, HIGH EROSIVE INDIAN COALS WERE INBUILT INTO THE
DESIGN OF SUBSQUENT UNITS.

Power Plant Summit 2008 – Optimised Design for Low Grade Indian Coals Power Plant Summit 2008 – Optimised Design for low Grade Indian Coals
 Bharat Heavy Electricals Limited, Tiruchirapalli Bharat Heavy Electricals Limited, Tiruchirapalli

PLANT LOAD FACTOR (%)

Rating 01-02 02-03 03-04 04-05 05-06 06-07
Total Thermal-
BHEL 71.3 74.1 74.3 75.7 74.9 78.4

500MW 80.1 82.3 81.4 84.5 82.2 84.2

250MW 86.7 90.5 88.3 91.0 85.5 92.5
200/210MW 75.3 78.1 79.1 79.0 78.3 82.3
OPERATING AVAILABILITY (%)
Rating 01-02 02-03 03-04 04-05 05-06 06-07
Total Thermal-
BHEL 81.7 83.9 83.9 84.3 83.4 84.7

500MW 88.2 89.5 88.9 90.1 87.8 86.7

250MW 91.0 93.0 90.2 92.1 88.4 93.0
200/210MW 84.9 87.4 88.3 87.6 87.3 89.2
Feedback
Power Plant Summit 2008 – Optimised Design for Low Grade Indian Coals Power Plant Summit 2008 – Optimised Design for Low Grade Indian Coals

Bharat Heavy Electricals Limited, Tiruchirapalli Bharat Heavy Electricals Limited, Tiruchirapalli

NTPC - Ramagundam 6 TEC, Trombay 500 MW

Record run – a tribute to high Trombay 500 MW

Unit:VI -
Operating standards Continuous run
for 366 days in
99-
99-00 without
Run continuously for 406 days from trip, meeting grid
Oct.4, 1994 to Nov.14, 1995 with PLF demand as reqd.
ranging from 85.49% to 101.83%.
Courtesy: Electric Power International Journal,USA (June 1996)
Awarded by Electric Power International, USA

Power Plant Summit 2008 – Optimised Design for low Grade Indian Coals Power Plant Summit 2008 – Optimised Design for Low Grade Indian Coals
 Bharat Heavy Electricals Limited, Tiruchirapalli Bharat Heavy Electricals Limited, Tiruchirapalli

WHY BHEL BOILERS?

• Well proven design for high ash Indian coals.
• Very high PLF/availability of the operating sets in India.
• Availability of field engineering expertise for sustained
performance of the plant.
• Established well experienced after sales service to meet
regular/ emergency requirements.
• Established O & M practices due to familiarity of
equipment.
• Easy availability of spares and services for the life of the Bharat Heavy Electricals Limited,
plant. Tiruchirapalli
Power Plant Summit 2008 – Optimised Design for Low Grade Indian Coals Power Plant Summit 2008 – Optimised Design for Low Grade Indian Coals