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VEERARAJAN
INTRODUCTION
Energy which is the key in moving the world in faster pace.
And this energy is generated in many ways. Among the various methods Thermal power generation is a important way of generating energy. Day by day , the fuel which runs these Thermal plants goes on decreasing. At a stage , it will come to stand still, but this may come earlier if we go on running our boilers in the conventional ways. There are lot of ways have been invented by many engineers and among them recycling the carbon rich fly ash back into the boiler is one way and we are going to do that now.
BOILER DEFINITION
According to ASME a steam generating unit or boiler is
defined as A combination of apparatus for producing, furnishing or recovering heat together with the apparatus for transferring the heat so made available to the fluid being heated and vapourised.
When an evenly distributed air or gas is passed upward through a finely divided bed of solid particles on a fine mesh, the particles are undisturbed at low velocity, as air velocity is gradually increased, a stage is reached when the individual particles are suspended in the air stream the bed is called fluidised and the process is called fluidization The Boiler using this mode of combustion principle is called as Fluidized Bed Combustion Boiler(FBC).
BUBBLING BED
CIRCULATING BED
ATMOSPHERIC (AFBC)
PRESSURISED (PFBC)
ATMOSPHERIC (ACFBC)
PRESSURISED (PCFBC)
LARGE HIGH
SMALL LOW
order of 850 to 900 C, so the volatile matter and the moisture in the un-burnts are expelled out. The un-burnt are only the fixed carbon. The calorific value of the fixed carbon is 8080 kcal/kg. By means of recycling this un-burnt carbon we can get reasonable amount of energy, by which the efficiency of the boiler can be improved.
1- 2 %
0.1 0.5 %
The losses tabulated in the AFBC column are taken from Thermax Boiler of 152 tonnes/hr @ MCL Tamilnadu.
15%
Ash produced per day
45 tonnes
15%
Ash collected at ECO and APH per day
6.75 tonnes
20%
Weight of un-burnt carbon present in ECO and APH ash per day.
1.35 tonnes
Recycled to furnace
LOSSES DUE TO UN-BURNTS IN FLY ASH OR LOSS ON IGNITION (LOI) BEFORE RECYCLING
L61 =
= ((80800.00351) + (80800.009945))/5300
= 2.045%
LOSSES DUE TO UN-BURNTS IN FLY ASH OR LOSS ON IGNITION (LOI) AFTER RECYCLING
L62 =
GCV of un - burnts from ESP 100 GCV of fuel
= (80800.009945)/5300 = 1.5 % It is found that the LOI gets decraesed by recycling the unburnt carbon in to the boiler
Out of the above two method indirect method is recommended for reliable operation of plant.
= 2.11149 4100 = Rs 8657.10(approx) Total amount of coal saved per year = 2111.49 365 = 770693.85kg = 770.693tonnes Total cost saved per year = 8657.109 365 = Rs 31, 59,844.785(approx)
ADVANTAGES
Thermal efficiency of the boiler increased Bulk fly ash LOI decreased Coal use decreased with no load reduction Lower fuel cost Lower ash handling cost Carbon in the fly ash burned at good efficiency over 80% Lower land fill cost Reduced pollution
FUTURE
150C. Increase in the excess air causes decrease in the efficiency of boiler, O2 at ECO outlet should be 3.5-4%. Excess air should be within 20-25% Un burnt carbon loss should be kept minimum by regulating excess air, distribution of primary and secondary air. There should not be any air leakage inside the furnace, it is achieved by closing inspection doors, openings, instrument openings, etc.,
for reliable operation of boiler Sampling of boiler water shall be carried out regularly to monitor its quality as recommended Removal of dissolved oxygen by deaeration in boiler
feed water is important to avoid pressure part corrosion and pitting feed water temperature at outlet of deaerator at the saturation temperature of the water at the operating pressure and the temperature of water entering economiser at 190 C.
RESULTS
Improving the efficiency of boiler upto 0.5% to 0.8%
Better utilisation of fuel by recycling the ash Fuel saved Cost saved per day Fuel saved Cost saved
= 2111.49 kg/day (approx) = Rs 8657.109 /day (approx) = 770.69 tonnes/yr (approx) = Rs 31,59,844.78 (approx)
QUESTIONS..?
THANK YOU