Fire Side Treatment

For
Solid Fuels
Coalmix & Biomix
Thermax
Chemicals
Content
Thermax
Chemicals
Introduction
Future of Solid fuels
Coal
Why ?
Global Perspective
Indian Perspective
Biomass
Why ?
Global Perspective
Indian Perspective
Problems in Coal fired Boiler
Problems in Biomass fired Boiler
Chemical Treatment
Coalmix
Function of Coalmix
Benefits of Coalmix
Dosing of Coalmix
Reference
Biomix
Function of Biomix
Benefits of Biomix
Dosing of Biomix
Measuring Performance
Targeted Boilers
Market Potential
Future of Solid Fuels
Fuel Oil Prices Moving Upwards Shift for
Cheaper Fuels.
Solid Fuel Cheap and Available in
Sufficient Quantity.
Solid Fuel Firing Multi Fuel Firing Option.
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Why Coal ?
Cheaper compare to Oil & Gas.
Large Coal Reserve in India. Available in Sufficient
Quantity.
New Clean Coal Technologies for coal firing. Less
pollution and more efficiency.
Ease in Handling & Storage compare to Liquid and
Gaseous Fuel.
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Coal - Global Perspective
World Coal Consumption is more than 6,000 million
tonnes per year (2004) and increasing at 2.5 % per Year.
World Coal Reserve is around 1,000,000 million tones.
China is biggest consumer of Coal followed by USA and
India.
EIA international energy review
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Coal - Indian Perspective
India is third largest Coal Consumer in world with 473
million tonnes per year (2006).
Coal Consumption in India is increasing with the rate 2.7
% per year.
Coal Reserve in India is around 100,000 million tonnes
(Exploitable Reserve) . Forth largest in world.
EIA international energy review
India Energy Forum 2006-07
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Why Biomass ?
Fossil fuels - oil, coal and gas - are key contributors to
global warming.
Limitation of fossil fuel reserves which are expected to
lost in next 40 or 50 years.
Low cost of Fuel & advantage if locally available in
sufficient quantity.
Less Difficulties in Handling & Storage compare to Liquid
and Gaseous Fuel.
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Biomass fuel - Global Perspective
In USA biomass energy account for around 3.2 % of total
consumption.
In Europe biomass energy account for around 2 % of
total consumption.
Around world biomass energy account for only 0.7 % of
total consumption.
EIA international energy review
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Biomass fuel - Indian Perspective
Biomass fuels used in India account for about one third
of the total fuel used in the world.
Biomass is most important fuel used in over 90% of the
rural households and about 15% of the urban
households.
Estimate potential for biomass energy in India is more
than 20000 MW.
Currently around 256 MW of biomass energy is
generated. (mostly by Bagasse)
Ministry of Non-Conventional Energy Sources, Government of India
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Problems in Coal fired Boiler
Slagging and Fouling: Mainly due to settling of
fine ash particles or gradual accumulation of
particles which form low melting point base
deposit.
Corrosion: Mainly due to High Sulfur content in
ash and Chlorine presence.
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Problems in Biomass fired Boiler
Slagging and Fouling: Cause by presence of
alkalis, such as sodium and potassium in
biomass.
Corrosion: largely due to the high potassium and
Chlorine content in biomass fuels.
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Chemical Treatment
By
Thermax Chemical Division
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Chemical Treatment
Coal* Fired Boiler / Heater
By
Coalmix
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Chemicals
* In case of Multi-fuel firing boiler, Coalmix
can be used if Coal proportional is > 50 %
Function of Coalmix
Coalmix is a multi-component coal additive in
powder form.
contains combustion catalyst, slag modifier and
corrosion inhibitor.
modifies deposit and prevents hard bond
formation.
Speed-up the combustion.
Retards SO3 formation and provide protection
against corrosive ash.
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Benefits of Coalmix
Reduces Deposition on Boiler Refractory
Reduces Corrosion on Boiler Refractory
Reduces Frequency of Shutdown
Improvement in Steam Generation by Keeping
surface clean.
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Dosing of Coalmix
Coalmix is available in Powder Form.
Based on coal consumption the required quantity of
Coalmix can be calculated.
Generally 1 kg of Coalmix required per 4-8 tonnes of
coal consumption.
To be dosed directly into combustion zone once in a day
as a shock dose.
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Chemical Treatment
Biomass* Fired Boiler / Heater
By
Biomix
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* In case of Multi-fuel firing boiler, Biomix can
be used if Biomass proportional is > 50 %
Function of Biomix
Biomix is a multi-component fuel additive in
powder form.
contains slag modifier and corrosion inhibitor.
alters chemical nature of deposit and forms
protective film on surface.
contains alkaline compounds which neutralizes
corrosive product of chlorine.
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Benefits of Biomix
Reduces Deposition on Boiler Refractory
Reduces Corrosion on Boiler Refractory
Reduces Frequency of Shutdown
Improvement in Steam Generation by Keeping
surface clean.
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Dosing of Biomix
Biomix is available in Powder Form.
Based on fuel consumption the required quantity of
Biomix can be calculated.
Generally 1 kg of Biomix is required per 4-8 tonnes of
fuel consumption.
To be dosed directly into combustion zone once in a day
as a shock dose.
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Measuring Performance of Coalmix / Biomix
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Chemicals
Stack temp v/s Months
145
150
155
160
165
170
175
180
185
1 2 3 4 5 6 7 8 9 10 11 12 13
Months
S
t
a
c
k

t
e
m
p

Incr easing Temp wit hout t r eatment
Sust aining Temp with
t r eat ment
Reducing Temp. with
t r eat ment
Tr eat ment star t
Measuring Performance of Coalmix / Biomix
Thermax
Chemicals
Ef f iciency % v/s Mont hs
80
81
82
83
84
85
86
87
1 2 3 4 5 6 7 8 9 10 11 12 13
Months
E
f
f
i
c
i
e
n
c
y

%
Incr easing Ef f iciency
wit h t r eat ment
Sust aining Ef f iciency
wit h t r eat ment
Drop in Efficiency Without treatment
Tr eat ment st ar t
Reference : Oriental Rubber Industries Ltd., Pune
System Details
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Sr No Parameter Details
1 Type of Boiler Smoke tube Coal fired Boiler
CPD-50 Thermax
2 Capacity 5 Tons per day
3 Working Pressure 10.5 Kg / cm2
4 Design Temperature On Heating Surface144 degree C
5 Type of Fuel Coal ( Indian / Indonesia )
6 Coal Consumption ~ 8 Tons per day
Reference : Oriental Rubber Industries Ltd., Pune
Problem Reported by Customer
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Chemicals
Regular shutdown of boiler due to increase in Stack
Temperature (from 200
o
C to 260
o
C).
Detrimental scale formation in smoke tubes.
Reference : Oriental Rubber Industries Ltd., Pune
Following Parameters were freezed to Monitor
the Treatment performance
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Comparison between Pre-treatment & Post-
treatment results
Stack Temperature
Smoke Index
Visual observation of Scale
Reference : Oriental Rubber Industries Ltd., Pune
Smoke Index Before and After Treatment
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Sr No Date
Smoke
index With
out
treatment
Date
Smoke
index With
treatment
1 7-Dec-06 9 25-J an-07 7
2 7-Dec-06 8 25-J an-07 7
3 7-Dec-06 9 3-J an-07 7
4 8-Dec-06 8 3-J an-07 7
5 8-Dec-06 9 3-J an-07 6
6 11-Dec-06 8 3-J an-07 7
7 11-Dec-06 9 9-J an-07 6
8 11-Dec-06 9 9-J an-07 6
9 11-J an-07 7
10 11-J an-07 6
Reference : Oriental Rubber Industries Ltd., Pune
Hard deposits - Difficult to remove (on 18th December
06 Pre-treatment)
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Reference : Oriental Rubber Industries Ltd., Pune
No Deposits - Clean Tube (On 18th J anuary 07- Post-treatment )
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Reference : Oriental Rubber Industries Ltd., Pune
Results
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Parameters Before
treatment
With
treatment
Stack Temp.
(After 1 month
of shutdown)
260
o
C 220
o
C
Smoke Index
(avg.)
8.6 7.0
Scaling
Observed
Yes No
Reference :
Oriental Rubber
Industries Ltd.,
Pune
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Chemicals
Potential Thermax Boilers
For
Coalmix / Biomix
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Chemicals
COMBIPAC
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COMBIPAC
Fuel: Multifuel Option
Agro Fuel & Biogas
Conventional Fuel like Coal, Lignite, Oil & Natural gas
Dosing Point: Fire Door / Inspection Door
Dosing Quantity: 1 kg of Coalmix (Coal Fired Boiler) / Biomix (Biomass Fired
Boiler ) for 4 to 8 (Tonnes of Fuel)
Dosing Method:
Calculate Dosing Quantity of Fuel Additive for One Day.
Apply calculated Quantity in Furnace as Shock Dose through Dosing Point.
Requirement of dosing of chemical is that the area where we are adding the
chemical, their temperature should be more than 350
o
C
Keep Damper opening at minimum level during application of the chemical.
If soot blowing facility is available, better use it after chemical application.
Packing: Coalmix / Biomix is in Powder Form and available in 25 Kg polythene lined
bag.
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HUSKPAC
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HUSKPAC
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Fuel: Husk (Design for Rice Mills)
Dosing Point: Fire Door / Inspection Door*
Dosing Quantity: 1 kg of Biomix (Biomass Fired Boiler ) for 4 to 8
(Tonnes of Fuel)
Dosing Method:
Calculate Dosing Quantity of Fuel Additive for One Day.
Apply that Quantity in Furnace as Shock Dose through Dosing Point.
Requirement of dosing of chemical is that the area where we are
adding the chemical, their temperature should be more than 350
o
C
Keep Damper opening at minimum level during application of the
chemical.
If soot blowing facility is available, better use it after chemical
application.
Packing: Coalmix / Biomix is in Powder Form and available in 25 Kg
polythene lined bag.
* If Force Draft; put off the fan during dosing of chemical.
MULTIPAC
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MULTIPAC
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Fuel: Coal, Lignite & Wood
Dosing Point: Fire Door / Inspection Door*
Dosing Quantity: 1 kg of Coalmix (Coal Fired Boiler) / Biomix (Biomass
Fired Boiler ) for 4 to 8 (Tonnes of Fuel)
Dosing Method:
Calculate Dosing Quantity of Fuel Additive for One Day.
Apply that Quantity in Furnace as Shock Dose through Dosing Point.
Requirement of dosing of chemical is that the area where we are
adding the chemical, their temperature should be more than 350
o
C
Keep Damper opening at minimum level during application of the
chemical.
If soot blowing facility is available, better use it after chemical
application.
Packing: Coalmix / Biomix is in Powder Form and available in 25 Kg
polythene lined bag.
*If Force Draft; put off the fan during dosing of chemical.
MULTITHERM
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MULTITHERM
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Fuel: Coal, Husk, Baggase & Wood
Dosing Point: Fire Door / Inspection Door
Dosing Quantity: 1 kg of Coalmix (Coal Fired Boiler) / Biomix (Biomass
Fired Boiler ) for 4 to 8 (Tonnes of Fuel)
Dosing Method:
Calculate Dosing Quantity of Fuel Additive for One Day.
Apply that Quantity in Furnace as Shock Dose through Dosing Point.
Requirement of dosing of chemical is that the area where we are
adding the chemical, their temperature should be more than 350
o
C
Keep Damper opening at minimum level during application of the
chemical.
If soot blowing facility is available, better use it after chemical
application.
Packing: Coalmix / Biomix is in Powder Form and available in 25 Kg
polythene lined bag.
MULTIMAX
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MULTIMAX
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Fuel: Coal, Husk, Baggase & Wood
Dosing Point: Fire Door / Inspection Door
Dosing Quantity: 1 kg of Coalmix (Coal Fired Boiler) / Biomix (Biomass
Fired Boiler ) for 4 to 8 (Tonnes of Fuel)
Dosing Method:
Calculate Dosing Quantity of Fuel Additive for One Day.
Apply that Quantity in Furnace as Shock Dose through Dosing Point.
Requirement of dosing of chemical is that the area where we are
adding the chemical, their temperature should be more than 350
o
C
Keep Damper opening at minimum level during application of the
chemical.
If soot blowing facility is available, better use it after chemical
application.
Packing: Coalmix / Biomix is in Powder Form and available in 25 Kg
polythene lined bag.
VERTICAL THERMOPAC
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VERTICAL THERMOPAC
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Fuel: Coal, Lignite & Biomass Fuel (Husk, Baggase etc.)
Dosing Point: Fire Door / Inspection Door
Dosing Quantity: 1 kg of Coalmix (Coal Fired Boiler) / Biomix (Biomass
Fired Boiler ) for 4 to 8 (Tonnes of Fuel)
Dosing Method:
Calculate Dosing Quantity of Fuel Additive for One Day.
Apply that Quantity in Furnace as Shock Dose through Dosing Point.
Requirement of dosing of chemical is that the area where we are
adding the chemical, their temperature should be more than 350
o
C
Keep Damper opening at minimum level during application of the
chemical.
Packing: Coalmix / Biomix is in Powder Form and available in 25 Kg
polythene lined bag.
Market Potential
Based on
Thermax PHD Boiler Sales
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Basis
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Based on PHD sales data From year 2000 to 2006
It is assumed that PHD boilers are operating on 50%
capacity
Cost of Coalmix / Biomix is consider as Rs 120 @Kg.
Dosing Quantity is calculated based on 1 kg : 6 Tonnes
ratio
Potential for Coalmix & Biomix
Rs. 25 Cr
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Thank You
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