WELCOME

TO

THE PRESENTATION
ON

MILLING SYSTEM NTPC - SIMHADRI

MILLING PLANT SPECIFICATION

TYPE OF MILL NO OF MILLS PER BOILER NO OF MILLS REQUIRE FOR FULL LOAD MILL CAPACITY PF FINENESS XRP 1003 (MPSP) 9 6 66.2 TPH 70% THROUGH -200 MESH 42 RPM 525 KW, 3.3 KV, 589 RPM 230 C 2 NOS 2 NOS

MILL SPEED MILL MOTOR RATING

MILL INLET AIR TEMP PA FANS (COMMON) SEAL AIR FANS (COMMON)

COAL CHARACTERISTICS
GCV ASH 3450 3600 KCAL/KG > 40 %

VM
CARBON MOISTURE

20 24 %
20 33 % 12 16 %

HGI

55

CONSTRUCTION & DESIGN FEATURES

SIMHADRI IS THE FIRST COASTAL BASED COAL FIRED THERMAL POWER PROJECT OF NTPC
BHEL HAS PROVIDED MILLS WITH MPSP (MILL PLANT SUPER PERFORMANCE) SYSTEM AT DESIGN STAGE, FIRST TIME IN NTPC TALL TOP CLASSIFIER MODIFIED VENTURI ( ALSO CERAMIC LINED) FLAP TYPE MILL DISCHARGE VALVE (CERAMIC LINED) BEARINGLESS SPRING LOADING DOUBLE BEARING JOURNALS MODIFIED VANE WHEEL ASSEMBLY CERAMIC LINED BENDS, INNER CONE, ORIFICES CERAMIC CARBIDE DUO CAST GRINDING ROLLS

CONSTRUCTION & DESIGN FEATURES

SPRING LOADED FLOATING FOUNDATION HIGH CHROME BULL RING SEGMENTS BURNER INLET ISOLATION VALVES FEEDER DISCHARGE ISOLATION VALVE DUST GAURD SEAL JOURNAL TILTING

CE VS MPSP DESIGN
S.NO 1 PARAMETERS GRINDING ROLL (GR) CE NI-HARD MPSP DUO CAST WITH CERAMIC CARBIDE INSERTS

2
3 4 5 6

BULL RING SEGMENT (BRS)

VANE WHEEL EXPECTED RUNNING HOURS PM SCHEDULE COST OF GRINDING ELEMENTS (GR + BRS)

NI-HARD
45 3000 BI-WEEKLY ~ 3 LACS

HIGH CHROME
30 11000 FOUR WEEKLY ~ 13 LACS

MILL MAINTENANCE PRACTICES & STRATEGIES

REGULAR AND PERIODIC PREVENTIVE MAINTENANCE CONDITION / WALKDOWN BASED MAINTENANCE

PLANNED MAINTENANCE (MAJOR)

BREAKDOWN MAINTENANCE

TIMELY PLANNING OF SPARES AND CONTRACTS

OPTIMIZATION / MODIFICATIONS

MILL MAINTENANCE PRACTICES & STRATEGIES

REGULAR AND PERIODIC PREVENTIVE MAINTENANCE CONDITION / WALKDOWN BASED MAINTENANCE

PLANNED MAINTENANCE (MAJOR)

BREAKDOWN MAINTENANCE

TIMELY PLANNING OF SPARES AND CONTRACTS

OPTIMIZATION / MODIFICATIONS

MILL PERFORMANCE FACTORS

MILL CAPACITY PF FINENESS MILL REJECTS MILL OUTLET TEMPERATURE MILL BOWL DP MILL POWER CONSUMPTION

MILL PERFORMANCE FACTORS

MILL CAPACITY DEPENDS UPON FOLLOWING FACTORS HARD GROOVE INDEX TOTAL MOISTURE CONTENT AIR FLOW PF COAL FINENESS

MILL PERFORMANCE FACTORS

PULVERISED COAL FINENESS
THE RECOMMENDED PF COAL FINENESS IS ABOVE 70% AND 98.0 % THROUGH 200 MESH AND 50 MESH RESPECTIVELY INITIAL FINENESS ACHIEVED : 60 TO 70% THROUGH 200 MESH &MORE THAN 2% RETENTION ON 50 MESH ADJUSTMENTS DONE DURING PG TEST: INCREASE IN SPRING COMPRESSION : 9.5 TO 11.5 TONS INCREASE IN VENTURY COLLOR HEIGHT : 50 MM REDUCTION IN INVERTED CONE CLEARANCE : 30 MM REMOVAL OF AIR RESTRICTION PLATE CLASSIFIER SETTING : FROM 3 TO 5

MILL PERFORMANCE FACTORS

MILL REJECTS DENSITY BASED SEPARATION ON THE BOWL LEADS TO MILL REJECTS AT SIMHADRI, THE MILLS ARE REJECTING THE MATERIALS WHICH ARE DIFFICULT TO GRIND LIKE STONES AND PYRITES. THE TOTAL MILL REJECTS ARE AROUND 2-10 KG PER HOUR STONE IS VERY LESS IN RAW COAL

MILL PERFORMANCE FACTORS

MILL OUTLET TEMPERATURE GENERALLY THE RECOMMENDED VALUE OF MILL OUTLET TEMPERATURE IS 100-X (X = % OF VOLATILE MATTER IN THE COAL) AT SIMHADRI WE ARE MAINTAINING THE MILL OUTLET TEMP AT 75 TO 85C AS THE VOLATILE MATTER IN OUR COAL IS LESS AND THE MOISTURE IS HIGH

MILL PERFORMANCE FACTORS

MILL BOWL DIFFERENTIAL PRESSURE THE RECOMMENDED VALUE BOWL DP IS 300 MMWC AT FULL LOAD HIGHER ASH CONTENT, HIGHER REJECTION, LOW AIR FLOW, EXCESS FINENESS AND ERODED MILL INTERNALS LEAD TO HIGHER BOWL DP

POWER CONSUMPTION
THE POWER CONSUMED BY THE MILL MOTOR SHOULD NOT EXCEED THE RATED CAPACITY. AT SIMHADRI THE CURRENT DRAWN BY MILL MOTOR AT FULL LOAD IS WELL WITHIN THE LIMITS

OPTIMISATION OF BOWL MILL PARAMTERS

IT IS ALWAYS SUGGESTED THAT BOWL MILL PARAMETERS SHOULD BE OPTIMIZED FOR SATISFACTORY PERFORMANCE OF THE MILLS AND TO IMPROVE THE LIFE OF MILL COMPONENTS AT SIMHADRI PG TEST IS JUST COMPLETED. OPTIMIZATION OF SPRING COMPRESSION IS IN PROGRESS

MODIFICATIONS
THE FOLLOWING MODIFICATIONS WERE DONE WITHOUT AFFECTING THE MILL DESIGN/FLOW CONDITIONS (DURING ERECTION & COMMISSIONING) :
LUBE OIL SKID RELOCATION INCREASE OF DISCHARGE PIPE DIA OF LUBE OIL SYSTEM FRO TO 1DURING COMMISSIONING

LOCKING SYSTEM MODIFICATION OF JOURNAL STOP BOLT

EXTENSION OF SPRING SHAFT

PROVISION OF ON-LINE MILL REJECT CHOKING REMOVAL PORT

DATA FOR MILL PERFORMANCE FACTORS AT SIMHADRI S.NO. 1) DESCRIPTIOIN Capacity Fineness X Passing through200 mesh) 02) Retention on 50 mesh 03) 04) Mill outlet Temp. Bowl DP 2.00% 87 deg c Maxm 300 mm WC <1% 80-85 deg c 300 to 340 mmWC RATED PARAMETERS 66.3 tph >70%

ACTUAL PARAMETERS
65 >80%

05)
06) 07)

Mill Amperage Mill

Rejects OTHERS, Volatile matter

137A

120-125A
Low

22min 12.00% 265 deg c 95 tph 55 3300 Kcal/kg ~40

<22%

Moisture
Mill air inlet temp. PA Flow HGI GCV Ash

.12-14 %
250 -270 deg c 90-105 tph >55 ~3300 k cal/kg >40

THANK YOU