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The boiler parameters are 15 TPH, 64kg/cm2 g, 485 deg C with feed water temperature at 105 deg C.
Design fuel is 100% rice husk. The boiler is provi ded underbed feeding system of rice husk. The
boiler is bottom supported at water drum level. The bed coils are bottom supported. There are two
compartments. Totally six 150 nb husk feed lines are used. Boiler is with radiant SH ( prim ary) and
secondary S H, boiler bank, econom iser and airpreheat er. Husk is fed by rotary feeder. Boiler was
originally designed for under bed firing system a nd over bed fuel. Over bed feeding system was
commissioned in the month of November 2004.
The boiler was later m odified for multi fuel agro fu el firing. The fuels curren tly fired are rice husk,
Channa gram straw, Ground nut shell, Soya straw.
The following are the problems reported and the requirements by the plant.
1. There is variance in Su perheated Steam tem perature betw een 455 0-5400C whereas the desired
range is 485 50C. This is to be reduced.
2. There is frequent variation in steam pressure w hereas the requirem ent is a constant pressure of
75.0 kg/Cm2.
3. Fuel consumption per KWH is very high 1.70 whereas the desired Fuel consumption per KWH is
1.25.
4. Auxiliary power consumption of the plant is 20% and this is high.
5. There is no control on the sizing and percentage fine s, moisture content and calorific value of the
fuel being used for the boiler. But whatever is the situation, optimum output from power plant is
desired against existing reduced output of a level 80-82%. Up to Sept. 2006, a maxim um o f
40% Soya straw, Gram straw & Mustard stra w were used. The steam param eters were under
control and turbin e capacity utilisation was at 9 0-95%. But af ter increasing the fibrous fuels to
100%, overheating of super heater tubes took pl ace. Once m elting of s uper heater tubes took
place. In the month of Sept 2009, complete set of super heater tubes replaced with new one.
6. Turbines nozzle chest body cracking was expe rienced in the m onth of Nov 2011. Steam
temperature excursions need to be under control to avoid this problem.
7. An optimized fuel feeding arrangement of a combination of agro based fuels having less calorific
value compared to rice husk is required. The SPM from the boiler stack while using such fuels.
8. The suitability of existing super heater tube ar rangements in the boiler needs to be reviewed for
the fuels being used currently.
9. We want som e type of autom ation with regard to controlling the tem perature of the super heater
tubes within the OEM recommended range and its interlocking with boiler feeding system.
10. The rated MCR of the boiler is desired using a m ixture Soya straw, Gram straw, Mustered straw
and other local fuels.
11. The Superheated Steam temperature has to be under control in the desired range of 485 50C.
12. The steam pressure variance has to be avoided.
13. The boiler efficiency needs to be improved and power consumption needs to be reduced.
The rice husk fuel GCV is reported as 3150 Kcal/ kg and with a m oisture of 8.68%. This matches
with the standard analysis adopted for boiler design.
The furnace design calculations are m ade and enclosed in annexure 5. The cal culations are made for
15 TPH output. For underbed firing 20% excess air h as been considered. The findings are as belo w.
The furnace layout is made and the furnace volu me is calculated from drawing. The present furn ace
volume above the bed is working out to be 52.456 m3. The present bed cross section is 2.95 m x 2.95
m. The area is 8.7 m2. The fluidisation velocity works out to be 2.74 m/s as against a requirement of
2.6 m/s and less. The DP nozzle pressure drop with 10% secondary air works out to be 162 mmWC.
This is in order. The bed coil length imm ersed in the bed works out to be 237 m as against
requirement of 226 m. The gas residence time in the furnace works out to be 2.2 sec.
Agro fuels are low den sity fuel s and bulk density ranges from 90 kg/m3 to 120 kg/m 3. They also
have high volatile matter with a minimum of 50%. We may see the fuel analys is report given by the
plant personnel in annexure 4. Due to this fact any overb ed feeding of agro fuels n eed more furnace
volume. As the moisture content increases, even as much as 3-4 seconds of furnace residence tim e is
provided. After the site visit a nd drawing study, it is found possible to increase the f urnace volume
by lowering the DP plate. As such the underbed feeding system is troublesome due to fibre content in
fuel and the stones. It is seen that the dechoking is being done regularly re sulting in drop in steam
pressure and temperature during such time.
Due to above problem , it is proposed to adopt open hopper design with sparger air nozzles to drain
off the stones and to go for 100% overbed feeding of all fuels. With this concept we can go for a 1.5
m pit below the open hopper.
Thermax them selves have supplied boiler for agro waste with such arrangem ent. See the
arrangement in annexure 6. Open hopper com bustor design is offered by many boiler m akers for
sponge iron plants where the fuel ash contains have iron particles.
Combustor design of the boiler for 100% rice husk by over bed feeding new
The agro fuels m oisture conten t varies and GCV also varies depend ing upon th e decay during
storage. Currently the fuel m ix GCV reported at plant is 3320 kcal/kg for underbed fuel m ix
(moisture 7.78%) and 3640 kcal/kg (m oisture 9.1%) for overbed fed soya straw. The ash for
underbed fuel mix is reported to be 5.98% a nd 2.88% for overbed. For design check, 100% overbed
firing of rice husk is considered, as this is the w orst fuel and a cons istent analysis is available from
many plants.
A layout is m ade with the proposed m odification of the boiler. See view s of the drawings in
annexure 7. The m odification suggested is extension of waterwall below the present operating floor.
With this the effective furnace volume (above bed) is seen to increase from 52.456 m3 to 85.4 m3.
The furnace design calculations are m ade and enclosed in annexure 7. The cal culations are made for
15 TPH out put. The excess air will be in the range of 35% for overbed com bustion of fuels. The
findings are as below. The furnace layout is made for the case of new com bustor and the furnace
volume is calculated from drawing. See the figure in annexure 7.
The revised bed cross section is 3.145 m x 3.145 m. The bed cross sectional area is 9.89 m2. This
is due to removal of re fractory wa ll and du e to extens ion of waterwa ll itse lf to f orm f urnace
walls. The furnace wall tube OD is 63.5 and stud lengt h is 1 6 mm. The studs will b e lined with
high alumina phosphate bonded refractory. The fluidisation velocity works out to be 2.44 m/s for
15 TPH generation. Due to overbed com bustion, actual velocity at bed will be less by a factor of
0.9.
The residence time for 35% Excess air condition is seen to be 3.19 sec above the bed.
The heigh t gain by th is m odification will be 2.7 m etres. Due to th is the wate rwall pro jected
heating surface will increase by 4*3.24*2.7 = 36.72 m2. This will help in bring ing down the gas
inlet temperature at APH outle t. But the temperature can vary as per th e fines and dryness. It is
not possible to increase the furnace height any f urther. Furnaces with 4 seconds residence tim e
can handle the fuels more efficiently.
There will be no PA fan or SA fan requirem ent. Since the wind box pressu re will be around 450
mmWC and the furnace depth is 1.6 m (one side), the FD air its elf will suffice for turbu lence.
That is SA tapping will be from APH outlet itself. There will be power saving in this respect.
Since the combustion takes place overbed, the bed coil HTA comes down. The bed coil is formed
from the side waterwall tubes. The bed coils are studded with 5 x 4 pattern of SS studs. The front
wall and rearwall tubes now particip ate for heat transfer. The free b oard heat release will be as
high as 30%. Any adjustm ent required to achieve better bed temperature is possible by covering
the bed tube with refractory coating.
The new air nozzles are to be m ade of SS ti p. The DP drop is designed for 176 mmWC. About
25% of the air will be used for SA & fuel spreading.
The FD fan capacity and ID fan capacity are found to be inadequate. The fan flow and head data
are taken from the torq ue speed cu rve provided to us. See the details in the annexure 7. For 15
TPH steam generation, this will change. However looking at the present load of 12 TPH & the
high exit temperature, margin may be available to some extent. The fan KW may not change.
Some details about the modifications that are required are as below
Waterwall
The waterwall is extended to create additional furnace volume. In addition the openings are made
for overbed feeding of the both rice husk and mustard stalk. The over bed ports are lowered
appropriately. New seal boxes are added at all fuel feed points.
Waterwall support
At present the waterwall is supported at the extended header portion of front & rear bottom
headers. Now the waterwall is to be supported at the panel but at the sa me elevation. Support is
taken from the fins. The support is known as girth support.
Downcomer
The downcom er routing is changed. The waterw all bottom headers are now connected by the
four downcomers.
Bed coils
At present two rows of bed coil s are provided. For overbed feeding and for agro fuels, th e heat
transfer a rea of bed coils requ ired is less an d the extend ed waterwall area com e in to heat
transfer. For this the tw o side water wall tubes are bent to f orm the bed coils. The bed coils ar e
studded for erosion protection. Seal boxes are added at the bed coil zone. The bottom side of the
front waterwall and rear waterw all (about 1 m above air nozzle) are also studded and plastered
with heat conducting ref ractory. The refractory lining is for erosion protection of vertical tubes,
as they generally get polished in six years time.
Bottom drains
The bottom headers are now shifted below the concre te floor. There are f our drains provided in
the header ends. The drain piping are to be rerouted at site suiting the present layout.
Open hopper FBC furnace
Stones ingress in rice h usk and oth er agro fuels lead to defluidisation a nd accelerated bed coil
erosion. Open hopper FBC furnace is the ideal choice fo r rem oval o f stones without boiler
stoppage. The com bustion air is now supplied th rough five no sparger header fitted with SS
tipped air nozzles. The hopper is suspended from the waterwall bottom headers. There are four
outlets to this hopper. Each outlet is provided with roller gates for draining the bed material / bed
ash as the bottom thermocouples become dead due to settled stones. The sparger headers get air
supply from the hot FD air ducts. Each sparger header is provided with drain pipes for rem oving
the seeped bed material. These headers are provided with dampers for turning down the load and
for start up purpose.
There are six direct ash drain pipes provided directly below the over bed fuel feed points for
direct draining oversize stones.
The open hopper is sealed with waterwall bottom header with provisions for taking care of
differential thermal expansion.
In order to operate the hopper drain gates and ash drain gates, the presen t ground f loor is to be
excavated by 1.5 m. The approach to the pit is to be made from right side of the furnace.
Instrumentation for the fluidised bed
The bed therm ocouples are inserted in guide pipes from the bottom . There are eight
thermocouples envisaged. The gui de pipes are welded to the open hopper walls. The air box
pressure tappings are to be located at each of the sparger header.
Fuel feeding system- rice husk
One is that the furnace has to be lowered to have additional furnace volu me for burning of fuel
fed from overbed. For this total underbed feed sy stem has to be lowere d. Then the pit a rea will
have to be including the underbed and for the f uel cross drains. At present stone ingress is there
with rice husk. The mixing nozzles and cross dechoking requirement is quite frequent. Hence the
objection was about the free access for operat ion. When the bed is present with ash
accumulations falling from superheate r, the b ed fluidisa tion gets dis turbed. Hen ce overbed
feeding system was chosen.
Rotary feeder system i s now rem oved. To take of horizontal transportation to overbed feed
points, screw feeders are proposed. Screw feeders drop the fuel in to the over bed feed chutes
provided at the left side waterwall.
The air for pushing the fuel and fo r sealing is taken from main FD air duct itself. A 100 nb line
with a damper is provided at each of the four feed chutes.
Part of the overbed feed chute will be of SS material.
Screw feeders are to be provided with VFD. Each screw feeder is prov ided with slide ga te for
isolation purpose.
Fuel feeding system Fibrous fuels
At present there is single feed point at the furnac e. This is made as two num bers for better use of
furnace volume.
At present there is no control of over feeding of the fuel. In case of excess feeding the
superheater tem perature will shoo t and ther e is risk of hea der f ailures. To contro l this, a drum
feeder is added below the present hopper. This drum feeder is sa me as the one used in bagasse
fired boiler at sugar mills. This drum feeder is also to be provided with VFD.
The drum feeder discharge is bifurcated in to two and connected to over feed chutes. The furnace
side of chute is made of SS. Air for pushing and sealing is taken from FD header. Two no 100 nb
pipes with dampers are considered for this.
Secondary air system
The secondary air (SA) system is now m odified as explained he re. The existing SA headers are
used. New SS tube tips are welded to waterwall. These tips are inclined to promote turbulence for
volatile matter combustion and increased residence time for particles.
The air tapping for SA system is taken direc tly f rom the APH outlet. The SA headers a re
provided with draft tappings to indicate SA head er pressure. Two num ber draft gauges are to be
provided. The SA tappings are provided only at front and rear walls.
Refractory in seal boxes, waterwall and open hopper
Refractory castables are to be poured in all over bed chute seal boxes.
In the front and rear waterwall tubes at bed zone, refractory lining is done. This refractory is high
alumina plastic refractory. This is done only up to stud tips. Sa me is applicable for two vertical
tubes in side walls.
The bottom headers are refractory lined to protect direct heating of the headers. This is done by
high alumina castable to a thickness of 75 mm.
The open hopper is provided with 40 thick refractory tiles of IS 8 grade
Insulation
The extended portion of the waterwall is to be insulated with 100 mm t hick light resin bonded
mattress. The seal boxes are to be insulated with 40 mm thick mattress. Open hopper is not to be
insulated. The air ducts are to be insulated with 50 mm thick Light resin bonded mattress.
For further details, the detailed drawings would have to be referred.
OBSERVATIONS AT PLANT
The boiler was inspected during the shut down. Further the boiler was seen in operation as well. The
following are the observations at the plant. Some recommendations are given as well.
The fuel fee d point at present is with horizontal spreading air. The height of the SH coil bottom
from the fuel feed point is 2.3 m . This is too less. Hence the com bustion takes place around
superheater area resulting in te mperature swings. This has resulte d in burning of the superheater
alignment bands. When the modification is taken up the alignment bands have to be reinstated.
Mustard straw, GN she ll and soya straw contain alkali (Sodium , Potassium ) ash and this can
form ash de posits. The deposit effect is reduced by the silica ash from rice husk. Deposits are
seen at superheater sections. However it is seen, it is not to extent of blocking the passage.
APH tube plugging & failure occurs due to condensation of fuel moisture & fuel hydrogen. The
presence of rice husk ash m ay reduce the plugging to som e extent. The cold end tubes of APH
need replacement every two years.
See annexure 2- Fuel handling / feeding system
The m ix of fuels for underbed con tains fibres and long pieces. Generally th is poses bridging
problem above feeder and above venturi.
The stones present in this fuel m ix can block th e ventu ri. The stones settle at fuel cross and
demand frequent dechoking. The fu el consumption goes high due to this. Whenever fuel feeding
is disturbed in the furnace, the steam pressure & steam temperature would swing.
By overbed feeding both the proble ms are eliminated. At p resent, only 25% of the tota l fuel is
being handled by underbed. Open hopper desig n will eliminate the pro blem of PA line choking .
However hopper drains have to be operated as required to lower the settled stones.
The overbed feeding system needs an im provement. A rotating lev eller is required at the m ain
conveyor to ensure a fairly constant feeding is available. The present capacity of the conveyor
seems inadequate. Spillage is seen. The conveyor may be provided with skirt board to com plete
length or the increasing of belt speed may be reviewed with manufacturer.
The boiler is not leak proof on gas side. There ar e air ingress points. T hey can be seen in the
photographs in annexure 3. The air ingress from outside loads th e ID fan. This increases the
power consumption.
There is considerable air ing ress in the roof pane l. This m atters a lot with resp ect to second ary
combustion in superheater area.
Such leakag es are enco untered at m any plants . The causes are design defects, inc omplete seal
box work during boiler installation / maintenance. It is advised to seal the roof from leakages by
using plaster of paris. A typical photograph at another plant and the a pplication procedure are
presented in annexure 3.
Stones are present in the fuel fed in to th e b oiler. This af fects the f luidisation and leads to
overbed burning. The bed coil erosion also would ta ke place due to haphazard gas flow in the
bed.
The dechoking process in underbed is a nuisance for boiler operation personnel. There is no way
the stone ingress can be avoided. Also the sepa ration by any m echanical s creen system is not
possible.
Due to inad equate furnace volum e & heating s urface, the b oiler exit gas tem perature goes up to
211 deg C, even for a load of 12 TPH. There is a need to increase furnace heat transfer area to
reduce the exit gas temperature.
Due to bed defluidization, the bed tem peratures are seen to be haphazard. This m akes the bed
coils inefficient to heat trasfer. Thus freeboard temperatures rise further.
It is seen that the Trem a cyclone outlet draft is as high as -350 mmWC , whereas the fan design
itself is 370 mmWC.
It is seen that fuel m oistures are under control. This is seen to be less than 10%. As the
percentage goes higher, the boiler efficiency com es down and the flue gas quantity increases.
Boiler capacity will be derated mainly due to this factor.
Ash fouling is related to ash chem ical analysis. Presence of sodium and potassium in straw leads
to fouling and calls for periodi cal cleaning. This is unavoidable. Usage of sand as bed m aterial
and the mix of rice husk can bring down the fouling to some extent.
Conclusions
1. Combustor volum e can be increas ed to th e extent possible to take care of residence tim e
requirement. Thus problem s related to high exit temperature & high steam tem perature can be
controlled.
2. Elimination of PA fan results in power savings.
3. For em ission control Electros tatic p recipitator is advised. T his will r esult in power savings as
well. The fan head req uirement will com e do wn to 150 mmWC as agains t the present 370
mmWC. The power required by ESP is much lesser.
4. Overbed fuel feed control is the key point on swings of steam temperature. A leveller would help.
Further the rotary feeder, below the fuel su rge hopper will avoid the excess feeding even if there
is more feeding from conveyor.
5. Boiler efficiency is dependent on excess air, boiler exit temperature and fuel m oisture. The
combustion efficiency will be 80% theoretically. Actual efficiency would by lower by 2% due to
blow down, fuel GCV variance and fuel m oisture variance and fuel m ix consistency. Online O 2
meter / CO meter is recommended so that the incomplete combustion can be known immediately
by the operator.
It is fea sible to inc rease the furnace volum e in th e present boiler layout. The feasibility of lowering
the com bustor was studied at plant by our engi neer and discussions we re held. Based on the
problems fa ced in underbed feed system , it was proposed to switch over to open hopper system.
Accordingly the detailed layout drawings, produc tion drawings and specifications would be
furnished.
ANNEXURE 1 OBSERVATIONS INSIDE THE BOILER
Photo 01: Generally the boiler designed for Biom ass fuel should have large furnace volume in order to make
effective combustion. This boiler is originally designed for Underbed and later overbed provisions were made.
The free board height is physically measured to be 23 00mm only. So once the fuel enters the boiler it will fly
away to superheater zone allowing the combustion to occur in Superheater area. The least residential time of 3
Secs will not be able to achieved here.
Photo 02: The above picture shows the boiler design data. The boiler is originally designed f or rice husk f uel
and the fuel firing is only through underbed system. Hence furnace volume was designed optimally.
Photo 03: T he above photo is showing the condition of Secondary superheater support clamps. The clam ps
were seen to have failed long time ago. This is due to high gas temperature.
Photo 04: In one of the RSH coils, the binding clamp is bur nt off. The furnace te mperature so metimes
touches even 1000 Deg C. Due to this some clamps have got melted.
Photo 0 5: Along the CSH zone most of the suppo rt cl amps have failed and the coils have co me out of
position. This will restrict the flue gas path and thus leading the way to ash choking along the CSH flue path.
Photo 06: The Supports given for coil expansion for CSH coils have failed.
Photo 07: The Ash deposi tion is also seen in Economiser coil but its deposition rate is low as compared to
Superheater coils and Bank tubes. Sonic soot blower is installed in economiser zone.
Photo 08: It is seen that around 15 APH tubes are dum mied because of leakage. APH tubes are subject to
corrosion in agro waste. The flue gas moisture condenses inside the tube.
ANNEXURE 2 FUEL HANDLING / FEEDING DETAILS
Fuel Mixing Ratio:
Ground nut Shell + Gram staw - 35 Scoops per Shift (Grounut Shell 90% , Gram Straw 10% if
available)
So,
Note: Soya straw alone is fed into the bunker through Overbed. Other fuels are fed through Underbed.
Photo 01: The above photo shows the grinding of Ground nut shell and Channa straw together. Channa straw
will be fed into the bunker only if it is available.
Photo 02: The above photo shows the mixture of ground nut shell and gram straw. The size of Chan na straw
is vary ing and som etimes it causes choking above the ro tary fe eder. As the fiber content increases ro tary
feeder will not be able to handle this.
Photo 03: A tractor brings the rice hus k from nearby place and mixes it with Ground nut shell and Chann a
straw. The mixing is done by tractor.
Photo 04: The above photo shows the fuel mix done by tractor. At some place the volume of Ground nut shell
seems to be more and in some place the volume of rice husk is more.
Photo 05: This is the closer view of Ground nut shell, Rice husk & Gram straw mixed together. The size of
gram straw alone not uniform as this may sometime leads to choking in rotary feder, mixing nozzle throat.
Photo 06: There is an vibratory feeder in the fuel yard into which Soya straw is fed manually by worker. There
is no controlling for the size, foreign particle of the fuel.
Photo 0 7: Since the fuel is fed manually, there is n o regularity i n fuel flow in the overbed Conve yor. This
irregular fuel flow highl y impacts the main steam para meters as there is no R otary or Screw feeder on the
overbed bunker.
Photo 08: Irregular fuel flow throug h Overbed belt conveyor. Skirt board system is advised to avoid sp illage.
In addition a rotary leveller can be added to achieve somewhat uniform feeding. The belt spe ed may have to
be increased to avoid spillage.
Photo 10: Recently VFD i s installed at Overbed conveyor motor to control the convey or RPM and there by
controlling Steam parameters. This will work better with uniformity in fuel flow to the conveyor.
Photo 11: Irregular fuel flow through Overbed belt conveyor.
Photo 12: Recently the y had gone for VFD to Over bed conve yor motor to control the conveyor RPM an d
there by controlling Stea m parameter s. This will not wo rk unless there i s uniformity in fuel flow in the
conveyor.
Photo 13: This panel phot o shows th e interlock made between main st eam pressure and overbed conveyor
motor. The steam pressure set point is 62 Kg/cm2.
Photo 14: The closer picture showing th e physical appearance of Soya straw. This fuel can be fed in over bed
only.
Photo 15: Stones present in fuel.
Photo 16: Bulk density of different fuels. The bul k densitie s are f airly sa me. Howe ver flowability
can vary due to size distribution.
ANNEXURE 3 FLAME TEST AND AIR INGRESS REPORT
Photo 01: It i s found that t here is so me leakage in Eco/APH hopper. Due to this additional atm ospheric air
gets into the boiler leading to ID fan loading.
Photo 02: Some Air ingress has been observed in t he seal box where the Soot blower line i s located. All seal
box should be fully welded to avoid air ingress.
Photo 03: Air ingress along the boiler rear side panel.
Photo 04: Air ingress along the Radiant SH O/L header. It is seen that the sealing is not proper at roof.
Photo 05: The condition of roof panel is very poor as there is considerable amount of ash seen above the roof.
Entire roof panel needs in sulation rework as this lead s to poor efficiency and secondary com bustion at SH
area.
Photo 06: It is seen that the sparks are coming out of the roof panel. This is because the sealing is not good.
Photo 07: The above photo shows the application of Pl aster of paris for better sealing of roof. Thi s
avoids the air ingress from the roof. This insulation is so hard finished; the persons can walk over the
roof.
Photo 08: General drawing of plas ter of paris / Ce ment + Mineral wool + Sand m astic finishes on
insulation which helps on sealing. This shall be done at roof tube area.
Photo 09: This is a t ypical sealing arrangem ent in the roof zone where the superheater coils enters. 150 thk
mineral wool should be applied over t he seal box. Above that 12 thk plaster of paris has to be applied. Fi nally
it shall be covered with Hessian cloth with two coats of black bitumen paint.
ANNEXURE 4 OBSERVATIONS IN BOILER OPERATION
Photo 1: Stones present in bed ash.
Photo 2: Fuel lines being dechoked due stones ingress. Due to stones, there is fuel loss and there i s
operational disturbance.
Photo 3: Th e economiser outlet g as temperature will have to be around 260 deg C and APH outlet
gas temperature has to be around 160 deg C. The AP H outlet gas temperature is 211 deg C. There is
considerable heat loss roughly th e loss can be around 4.5%. The be d tem peratures are haphazard
indicating settling of bed with stones. The low temperatures can be due to over bed firing. The higher
amount of bed coil also causes this low temperature. This is with a less load of 11.5 TPH.
Photo 4: Trem a cyclone outlet dr aft is -350 mmWC. This is too high. Across dust collector nearly
290 mmWC drop is seen. The hot air tem perature is quite high. Normally it is designed for 150 deg
C.
Photo 5: The as fired moisture in fuel is well within control. GCV of fuel mix is also good.
Photo 6: The above is the data collected from plant on fuel ultimate and proximate analysis. The ash
analysis was not available. The fuel ash from mustard straw / soya straw / gra m straw can contain
alkalis which can deposit over the superheater tubes.
ANNEXURE 5- COMBUSTOR DESIGN CALCULATIONS FOR 100% RICE HUSK FIRING BY
UNDERBED
EWS 604
No off compartments 2
Total no of fuel feed points 7
Fan sizing
FD fan capacity (% MCR ) 100 %
FD fan efficency 75 %
ID fan capacity (% MCR) 100 %
ID fan efficency 75 %
PA fan capacity (% MCR ) 100 %
PA fan efficiency 70 %
Results Summary
Dry air required, kg /kg of fuel fired = 5.126 kg/kg
Wet air required, kg /kg of fuel fired = 5.272 kg/kg
Dry Flue gas produced, kg /kg of fuel fired = 5.419 kg/kg
Flue gas produced, kg /kg of fuel fired = 6.105 kg/kg
Constituents of fuel
H, Hydrgen = 5.077 %
M, Moisture = 8.68 %
A, Ash = 16.063 %
GCV, Gross calorific value of fuel = 3150 kcal /kg
HL1, % Heat lost through ash at a location 1 = 0.16063x (5 / 100 ) x0.22x (900-40) x 100 / 3150 %
HL1, % Heat lost through ash at a location 1 = 0.05 %
HL2, % Heat lost through ash at a location 2 = 0.16063x (5 / 100 ) x0.22x (300-40) x 100 / 3150 %
HL2, % Heat lost through ash at a location 2 = 0.01 %
HL3, % Heat lost through ash at a location 3 = 0.16063x (5 / 100 ) x0.22x (250-40) x 100 / 3150 %
HL3, % Heat lost through ash at a location 3 = 0.01 %
HL4, % Heat lost through ash at a location 4 = 0.16063x (5 / 100 ) x0.22x (140-40) x 100 / 3150 %
HL4, % Heat lost through ash at a location 4 = 0.01 %
HL5, % Heat lost through ash at a location 5 = 0.16063x (60 / 100 ) x0.22x (140-40) x 100 / 3150 %
HL5, % Heat lost through ash at a location 5 = 0.07 %
HL6, % Heat lost through ash at a location 6 = 0.16063x (20 / 100 ) x0.22x (140-40) x 100 / 3150 %
HL6, % Heat lost through ash at a location 6 = 0.02 %
Manufacturer margin
HLS7, Manufacturer margin = 0.5 %
Total efficiency break up
HLS1, Unburnt carbon loss = 1.36 %
HLS2, Total Heat loss through the ash = 0.17 %
HLS3, Heat lost through moisture in air = 0.18 %
HLS4, Heat lost through moisture & H2 in fuel = 10.87 %
HLS5, Heat lost through dry flue gas = 5.06 %
HLS6, Radiation loss = 1 %
HLS7, Manufacturer margin = 0.5 %
PA fan sizing
PA fan capacity (% MCR ) = 100 %
MCR fuel transport airflow required = 1.979 m3/s
MCR airflow of PA fan = ( 1.979x 100 / 100 ) m3/s
MCR airflow of PA fan = 1.979 m3/s
Margin on PA fan flow = 20 %
Design Flow for PA fan = 1.979 x ( 100 +20 ) / 100 m3/s
= 2.37 m3/s
PA fan Design head = 700 mmwc
Assumed PA fan efficiency = 70 %
PA fan operating power required = 100 x 2.37 x 700/ ( 101 x 70 ) kw
= 23.5 kw
PA fan operating power BKW required = 100 x 1.979 x 700/ ( 101 x 70 ) kw
= 19.6 kw
ID fan sizing
ID fan capacity (% MCR ) = 100 %
MCR gas flow produced = 9.20 m3/s
MCR gas flow of ID fan = ( 9.20x 100 / 100 ) m3/s
MCR gas flow of ID fan = 9.2 m3/s
Margin on ID fan flow = 20 %
Design Flow for ID fan = 9.2 x ( 100 +20 ) / 100 m3/s
= 11.04 m3/s
ID fan Design head = 370 mmwc
Assumed ID fan efficiency = 75 %
ID fan operating power required = 100 x 11.04 x 370/ ( 101 x 75 ) kw
= 53.9 kw
ID fan operating power BKW required = 100 x 20 x 370/ ( 101 x 75 ) kw
= 44.9 kw
Minimum motor power required = 1.15 x 53.9 kw
Minimum motor power required for ID fan = 62.0 kw
Results summary
FD fan PA fan ID fan supply
Design flow m3/s 6.89 6.83 2.37 2.17 11.0 10.5
Design head mmwc 750 750 700 700 370 370
Design temperature Deg C 40 150 160
Assumed effciency % 75 70 75
Operating power kw 68.2 23.5 53.9
Min motor power kw 78.4 27.0 62.0
Selected motor Kw kw 90 90 30 30 75 75
EWS 604
UNDER FED FLUIDISED BED SIZING Date & time : 12/30/12 7:55 AM
PROJECT : - 100% rice husk- as per lab report- underbed
Constituents of fuel
H, Hydrgen = 2.484 %
M, Moisture =8%
A, Ash = 46.65 %
GCV, Gross calorific value of fuel = 3515.42 kcal /kg
HL3, % Heat lost through moisture in air = Ww x Wd x {(Cp1 x Tb) -(Cp2 x Tca)}x 100 / GCV
= 0.02851x5.126x[(0.5685x850)-(0.3592x150]x100 /351
HL3, % Heat lost through moisture in air = 1.78 %
HL4, % Heat lost through moisture & H2 in fuel ={M+(8.94 x H)} x [595.4+(Cpb x Tb) -Ta] x 100 / GCV
HL4, % Heat lost through moisture & H2 in fuel ={ 0.08+ (8.94 x 0.02484)}x [ 595.4+(0.5685x 850) -
40]x100/3515.42 %
HL4, % Heat lost through moisture & H2 in fuel = 8.92 %
HL5, % Heat lost through dry flue gas =Qfgd x{ (Cp1 x Tb) - (Cp2 x Tca)} x 100 / GCV
=5.419x { ( 0.285478044013218 x 850) -
HL5, % Heat lost through dry flue gas = 31.80 %
Sign: Sign:
EWS 604
= 5.0077 m3/s
Cd, Coefficient of discharge = 0.7
Actual No of air nozzles = 641
Air velocity through a nozzle hole = 5.0077/ (641x0.00018)
= 44.21 m/s
Pressure drop at MCR condition = 0.796 x 44.21^2 / ( 2 x 9.81 x 0.7^ 2)
Pressure drop at MCR condition = 162 mmwc
Results summary
No off nozzles provided = 641
Selected distributor plate width = 2950 mm
Selected distributor plate length = 2950 mm
Pressure drop at MCR condition = 162 mmwc
Pressure drop at Min fluidisation condition = 326 mmwc
Sign: Sign:
ANNEXURE 6 OPEN HOPPER DESIGN FOR AGRO FUELS
Photo 1: Open hopper design supplied by Thermax for high ah coal.
No off compartments 2
Total no of fuel feed points 0
Fan sizing
FD fan capacity (% MCR ) 100 %
FD fan efficency 75 %
ID fan capacity (% MCR) 100 %
ID fan efficency 75 %
Results Summary
Dry air required, kg /kg of fuel fired = 5.767 kg/kg
Wet air required, kg /kg of fuel fired = 5.931 kg/kg
Dry Flue gas produced, kg /kg of fuel fired = 6.060 kg/kg
Flue gas produced, kg /kg of fuel fired = 6.765 kg/kg
Constituents of fuel
H, Hydrgen = 5.077 %
M, Moisture = 8.68 %
A, Ash = 16.063 %
GCV, Gross calorific value of fuel = 3150 kcal /kg
HL1, % Heat lost through ash at a location 1 = 0.16063x (5 / 100 ) x0.22x (900-40) x 100 / 3150 %
HL1, % Heat lost through ash at a location 1 = 0.05 %
HL2, % Heat lost through ash at a location 2 = 0.16063x (5 / 100 ) x0.22x (300-40) x 100 / 3150 %
HL2, % Heat lost through ash at a location 2 = 0.01 %
HL3, % Heat lost through ash at a location 3 = 0.16063x (5 / 100 ) x0.22x (250-40) x 100 / 3150 %
HL3, % Heat lost through ash at a location 3 = 0.01 %
HL4, % Heat lost through ash at a location 4 = 0.16063x (5 / 100 ) x0.22x (140-40) x 100 / 3150 %
HL4, % Heat lost through ash at a location 4 = 0.01 %
HL5, % Heat lost through ash at a location 5 = 0.16063x (60 / 100 ) x0.22x (140-40) x 100 / 3150 %
HL5, % Heat lost through ash at a location 5 = 0.07 %
HL6, % Heat lost through ash at a location 6 = 0.16063x (20 / 100 ) x0.22x (140-40) x 100 / 3150 %
HL6, % Heat lost through ash at a location 6 = 0.02 %
Manufacturer margin
HLS7, Manufacturer margin = 0.5 %
Total efficiency break up
HLS1, Unburnt carbon loss = 1.36 %
HLS2, Total Heat loss through the ash = 0.17 %
HLS3, Heat lost through moisture in air = 0.21 %
HLS4, Heat lost through moisture & H2 in fuel = 10.91 %
HLS5, Heat lost through dry flue gas = 5.90 %
HLS6, Radiation loss = 1 %
HLS7, Manufacturer margin = 0.5 %
ID fan sizing
ID fan capacity (% MCR ) = 100 %
MCR gas flow produced = 10.44 m3/s
MCR gas flow of ID fan = ( 10.44x 100 / 100 ) m3/s
MCR gas flow of ID fan = 10.44 m3/s
Margin on ID fan flow = 20 %
Design Flow for ID fan = 10.44 x ( 100 +20 ) / 100 m3/s
= 12.528 m3/s
ID fan Design head = 370 mmwc
Assumed ID fan efficiency = 75 %
ID fan operating power required = 100 x 12.528 x 370/ ( 101 x 75 ) kw
= 61.2 kw
EWS 604
ID fan operating power BKW required = 100 x 20 x 370/ ( 101 x 75 ) kw
= 51.0 kw
Minimum motor power required = 1.15 x 61.2 kw
Minimum motor power required for ID fan = 70.4 kw
Results summary
FD fan Supply ID fan supply
Design flow m3/s 7.86 6.83 12.5 10.5
Design head mmwc 750 750 370 370
Design temperature Deg C 40 165
Assumed effciency % 75 75
Operating power kw 77.8 61.2
Min motor power kw 89.5 70.4
Selected motor Kw kw 90 90 75 75
EWS 604
UNDER FED FLUIDISED BED SIZING Date & time : 12/30/12 8:20 AM
PROJECT : - 100% rice husk- as per lab report- OVERBED
Constituents of fuel
H, Hydrgen = 2.484 %
M, Moisture =8%
A, Ash = 46.65 %
GCV, Gross calorific value of fuel = 3515.42 kcal /kg
HL3, % Heat lost through moisture in air = Ww x Wd x {(Cp1 x Tb) -(Cp2 x Tca)}x 100 / GCV
= 0.02851x5.767x[(0.5685x850)-(0.3592x150]x100 /351
HL3, % Heat lost through moisture in air = 2.01 %
HL4, % Heat lost through moisture & H2 in fuel ={M+(8.94 x H)} x [595.4+(Cpb x Tb) -Ta] x 100 / GCV
HL4, % Heat lost through moisture & H2 in fuel ={ 0.08+ (8.94 x 0.02484)}x [ 595.4+(0.5685x 850) -
40]x100/3515.42 %
HL4, % Heat lost through moisture & H2 in fuel = 8.92 %
HL5, % Heat lost through dry flue gas =Qfgd x{ (Cp1 x Tb) - (Cp2 x Tca)} x 100 / GCV
=6.060x { ( 0.284594539902954 x 850) -
HL5, % Heat lost through dry flue gas = 35.43 %
Sign: Sign:
EWS 604
= 46.05 m/s
Pressure drop at MCR condition = 0.796 x 46.05^2 / ( 2 x 9.81 x 0.7^ 2)
Pressure drop at MCR condition = 176 mmwc
Results summary
No off nozzles provided = 529
Selected distributor plate width = 3144.5 mm
Selected distributor plate length = 3144.5 mm
Pressure drop at MCR condition = 176 mmwc
Pressure drop at Min fluidisation condition = 258 mmwc
Sign: Sign:
VIEWS OF BOILER WITH PROPOSED OPEN HOPPER COMBUSTOR MODIFICATIONS