• After improving the fineness emphasis has

been given on flame failure and secondary

air distribution in the furnace because
burning is possible if coal particles are
extremely fine and intimately mixed with
the combustion air. In order to intimately
mix the coal with air and for complete
combustion 2% excess oxygen levels are
needed. Most of the combustion problem
starts from this mixing of coal and air.
• . If the coal is of low VM and low GCV fuel air
damper opening is to be reduced to 20% and
auxiliary air less than 10%, (Wind box 60-80)
specially at the bottom of the furnace. The
measurement of oxygen with the help of zirconia
probe in flue gas for combustion control has to
be a routine requirement. The measurement of
CO in flue gas also gives better indication on
combustion control and Thereby controlling the
flow of secondary air fire outs & flame failures
can become nil.
 Unequal PC Flow
• If on running condition suddenly the P.C.Pipe
chocking is removed it leads to sudden accumulation
of fuel in furnace & furnace pressurization occurs..
• P.C.Pipe use to get chocked due to fall out of coal in
P.C.Pipes. Unequal distribution of air / fuel flow in the
furnace results in reach mixture of fuel on one side
and lean mixture on the other side. For equalization of
PC flow orifices are installed in P.C.Pipes to equalize
resistance in coal pipe of different lengths from the
pulverizer to the different burners. Dirty pilot test
usually carried out to know the PA velocity in
P.C.Pipes. The minimum transportation velocity in
P.C.Pipe is also checked so that no fall out occurs.
Minimum transportation velocity required for a
pulverized fuel is 25 Meters./sec.
 Clinkering Problem
Clinkering occurs due to following reasons:
1. Plan-area loading
2. Silica ratio
3. Base-acid ratio
4. Slagging ratio
5. Total alkali content.
6. Reduction in Initial deformation temperature
due to reducing condition and Unequal PC
flow.
 Causes of Clinkering
• While designing the boiler, the designer
considers plan area loading which is
Net heat release rate/ plan area. The burners
spacing should be selected in such a way that
plan area loading is within 3.75x106 kcal/m²h
and 4.73 x 106 kcal/m²h. The condition
aggravated due to the unequal distribution of
primary air flow. During the combustion the coke
splits into coke & the particles of incombustible
material called ash. The unequal PA flow causes
high temperature due to reducing environment in
the vicinity of burners. In a reducing atmosphere
ash fusion temperature reduces by 100-150°c.
 Contd..
• When this molten ash impinges on the cooler
water wall tubes, due to unequal distribution, the
clinkers formed. Dirty pitot test usually carried
out which indicated unbalanced P.C.flow, which
was causing chocking due to fall out or
impinging on the coal water wall tube. Orifices
installed in PC pipes. Actual flame temperature
was measured and bottom SAD opened in order
to reduce the temperature of the furnace so that
furnace temperature falls below ash fusion
temperature.
 Indian coal ash constituents
Constituents Formula Percentage

Silica SiO2 55-64

Alumina Al2O3 25-35

Iron Oxide Fe2O3 4-10

Calcium Oxide CaO 1.4-12

Magnesium Oxide MgO 0.4-4

Sodium Oxide Na2O 0.2-0.4

Potassium Oxide K2O 0.7-2.4

Titania TiO2 0.7-2.9

Sulphur Trioxide SO3 0.2-1.2