Uneven Coal Flow to the Boiler

Coal Flow Balancing

Effective control, balancing and monitoring of PF distribution provides:

Correct air to fuel ratio at burners

Minimum but safe transport velocity
Reduction in emissions
Monitor and Improved particulate fineness
Improved burn and stoichiometric conditions
Elimination of flame detachments
Reduction in PF system erosion
Reduction in carbon-in-ash
Reduction in PF system pressure drop
Saving volume and pressure of primary transport air.
Coal Fuel Boiler Optimization
Content of Presentation

1. Introduction mass flow Sensor

2. Introduction velocity Sensor
3. Examples from other Installations
Mass Flow Sensor
How do we masure?
 20% 25% 35% 20%

both values
meassured

mill
10 tons
 IntensiveMIC 3V3 10-08-04
Testing in Laboratory
14000
Vel. < 75 fps
Vel. < 95 fps 500
12000

400
Coal Mass Flow ( lbs/hr)

MIC System Signal (mv)

10000

8000
300

6000
Air/Coal ratio 1:1
200

4000

100
2000

0 0

PM

PM

PM

PM

PM
AM

AM

AM

AM

AM
AM

AM

AM

00

15

5
30

00

15

30

45
0

:1

:3

:1
:3

:0

:1

6:

2:
4:

1:

7:

3:

9:

08

34

00
46

12

38

:1

:4
:0

:3

:5

:2

:4

1:

1:

2:
8:

9:

9:

12

12
10

10

10

11

11

Time

Feeder;MIC
CoalFlow 100
mic-Signal; mic-Signal
2 Per. Gleitender Durchschnitt (CoalFlow 100)
sliding average
6 Per. Gleitender Durchschnitt (MIC)
 Measuring capabilities

Real Time coal flow monitoring for up to 8 pipes per mill

(no limitation for the number of mills)
Total fuel input (with calibration to feeder data)
Velocity in Coal Pipe
Temperature in Coal Pipe
Features

Safe: Microwave intensity is less than a cell phone

Clean: Dustfree installation and maintenance

Fast: Continuous measurement in all pipes, when

adjusting mass flow changes are immediately visible

Flexible: Measures black coal, lignite (brown coal) and

biomass
 How to install?

2 inch ball valve assembly

Diameter waveguide only 20mm

1 full port ball valve possible
 Location on Pipe
12

10

Spalte 1
6
Spalte 2
Spalte 3

4
Optimum Installation If vertical is not possible
vertical pipe roughly 1.5 yard after bend
2
three sensors 120 three sensors 120

0
Zeile 1 Zeile 2 Zeile 3 Zeile 4
 Velocity Sensor

Electrostatic Sensor (mobile Version) measures delay

between two signals
Output:
1. Velocity
2. Very fast Temperature measurement
3. massflow as Trend
 Examples

1. Black Coal
2. Lignite (Brown Coal)
3. Biomass (Dense Phase Flow)
 Total fuel output into coal pipes

Feeder speed

Superheater

Example black coal

Example Lignite (brown coal)
Example Lignite (brown coal)
Example Biomass
mic signal

Example Biomass
 Optimisation Example GKK Kiel

unscheduled power loss through partial blocked feeder

 Optimisation Example at Tri-State Craig
(Unit 1 % 2)

B & W 450 MW wall-fired units

Units are arranged as mirrored images

The Units exhibit different operating characteristics

relating to furnace slagging and steam attemperation
and NOX emissions.
 Combustion
Combustion Optimization
Optimization at Tri-State
at Tri-State Craig
Craig Unit 1&2
Units 1 & 2
Conditions before the test started

Unit 1s NOX production is approximately

.03 Lb/106 BTU less than Unit 2, regardless
of pulverizers out of service.

Unit 2 has a higher heat input to the right side

of the furnace.
 Before Optimization at Tri-State Craig Units 1 & 2
Combustion Optimization at Tri-State Craig Unit 1 & 2

Each colour represents a row of burners of one mill

Same colours left and right correspond to the same burners at each unit
Left axis in each diagram shows deviation from mean value
Unit 1 one is way out of balance compared to unit 2
Unit 2 has more coal input on the right side as expected
The Goal of Coal Balancing

Balanced heat input, eliminates the furnace hot spots.

- Will result in lower NOx production.

Balanced O2, with compartments out of service.

- If burners have high fuel input, they will have to be
tuned to have higher air flow to support that fuel
input. When taken out of service, these high input
burners will create air rich zones, which will
provide
larger volumes of excess air, that will enable NOx
production.
 After Optimization at Tri-State Craig Units 1 & 2
Combustion Optimization at Tri-State Craig Unit 1 & 2
U1 Coal Line Balance by Mills in service U2 Coal Line Balance by Mills in service

50 50

30 30
All Mills All Mills

% Deviation
% Deviation

10 A Out 10 A Out

B Out B Out
-10 4/8 3/7 2/6 1/5 -10 1/5 2/6 3/7 4/8
C Out C Out

-30 D Out -30 D Out

E Out E Out
-50 -50
Pipes Pipes

After calibration distribution is closer to the mean value

Still not perfect but with existing valves was no more adjusting possible
Heat distribution of boiler more even
Reduction of NOx
A further balancing would increase pressure drop to much
It is more cost effective to adjust the remaining unbalance with sec. air!
Example Optimization:
RenoDeMedici Arnsberg
Problem:
Very old boiler
Windbox system
old mills tend to block
Example Optimization:
Problem:
overall perfomance
 Hot Spot
CO NOx
high carbon in ash
less NOx
less CO
more O2 Flame
less carbon in ash
higher efficiency
Burner

adjust 25% 25% 25% 25%

Sensors

sec. air Reading sensors

30% 20% 28% 22%

adjust
massflow
manual
readjust
massflow mill
if necessary
Principle of Optimization:

Eucontrol active

Eucontrol inactive
Strategy of Optimization:
1. Measure Coal Flow & Velocity

2. Balance Mass Flow (once)

3. Measure secondary air

4. Adjust secondary air to coal flow

5. Measure CO in flue gas

6. Reduce excess air

References:
more than 2000 sensors installed worldwide
 mobile System

Data Aquistion Unit in Peli Case, with Touch Screen on request

Second pelicase for sensors, brackets, junction box and cable
If more than 12 sensors needed a third pelicase is required
Coal Flow
Trimming Valve:
A dedicated Coal Flow
Trimming Valve are provided
to balance the coal flow on
each pipes to the boiler.
The valve is design for coal
flow trimming, minimum loss
in flow with its unique
design.
Challenges the Air Flow
Measurement:
An air flow measurement that is not repeatable, accurate, or representative of mass
flow can destabilize the airflow control loop and leave you with virtually no control over
the fuel-to-air ratio.

Here are the primary causes of inaccurate air flow measurements:

Improper selection of measurement technology
Blockage of the flow element (due to plugged pitots or duct collapse)
Inadequate straight runs of duct upstream and downstream of the flow
measurement
Collapse, or blockage of flow straightening devices (honeycomb, etc.)
Change in duct size due to heat or pressure
Density (and thus mass flow measurement) is uncompensated by temperature
and static pressure
Measure the Air Flow Accurately:

Collaborate with renowned air flow sensor from

USA with extensive experience in providing the
accurate and robust engineered airflow monitoring
to measure primary, secondary and overfire air,
FGR and individual burner airflow measurement.

We also provide the unique Flow Conditioner to

straighten the flow, reduce turbulent and create an
accurate flow measurement.
Unique Reliable VAP3/PA
Pitot sensor :
The VAP3/PA pitot
places its high port
inline with airflow and
thus, has no impact
ports. Because the PA
pitot is not subject to
plug-ging, for most
applications, no purge
system is required.
Measure the CO, O2 in Flue
Gas
To accurate the measure of emission in the AFR
Optimizer is crucial, it works as the continuous
immediately feedback to the control.

Collaborate with the proven solution from USA, we

offers the single point carbon monoxide monitors,
(DMCCO-Single Point) specifically designed for use
on utility boilers. The cost effective design makes it
ideal for use in a grid format, designed for optimizing
combustion.
Measure the CO, O2 in Flue
Gas
Each DMCCO monitor includes a
Stainless Steel insertion probe,
manufactured to customer desired
length. Each monitor includes a full
array of gas conditioning, including a
two stage chiller, automatic moisture
removal and static second stage drying
of the process gas. CO monitoring is
done by Internal IR
bench. System includes Auto Zero of
the IR bench, and automatic purging
system for probe reliability.
Specification and Unique
Features of CO measurement
Multiple levels of moisture and water vapor separation ensures accuracy and
reliability

Automatically zeroes the nondispersive infrared analyzer to eliminate drift and

improve accuracy

Detect or Type : Single Pass, Non-dispersive Infrared

Sensitivity : 1ppm

Accuracy : 10 ppm (readings 100ppm); 5 %

(100ppm<readings20,000ppm); (System Field Calibrated to 2% at 1,000ppm
CO)
Thank you for listening!

Questions?