PulverizerOperation PerformanceandTesting

RodPifer
.1

CoalRecirculation
RawCoalFlow Product Output

FinalClassification GravitySeparation Primary Classification Fluidized Bed

.2

PrimaryAirControl CommonPAFan
ColdAir Duct Coalair TransportPipes Swing Valve Operators

HotAirDuct Tempering AirControl Damper

HotAir Control Damper

Flow

Primary Air Damper

Pitot Tubes

Shutoff Damper

Pulverizer

.3

CoalPropertiesAffectingPulverizerSelection
Basicratingformula
Correctedcapacity= BasecapacityxCgxCf xCm

Grindability (Cg)
Effectoncapacity Asaffectedbymoisture

Fineness(Cf)
Effectoncapacity Requirementsforfuelrank

Moisture(Cm)
Effectoncapacity Effectsonsurfaceandinherentmoisture

.4

RelativePulverizerCapacityasaFunctionof Hardgrove Grindability

1.6 1.5 1.4 1.3 1.2 1.1

Pulverizer Capacity Correction Factor,Cg

1.0 .9 .8 .7 .6 .5 .4 .3 .2 .1 0 0 10 20 30 40 50 60 70 80 90 100 HGIASTMD409

.5

B&WPulverizerCapacityCorrectionwith200 MeshFinenessStandardClassifier
1.2

Pulverizer Capacity Correction Factor,Cf

1.0

.8

.6 50

60

70

80

90
.6

FinenessPercentPassing200Mesh

B&WPulverizerCapacityCorrectionDuetoMoisture
1.05 1.00

Pulverizer Capacity 0.97 Correction Factor,Cm

0.95

0.93

10

12

SurfaceMoisture(%byweight)
.7

Grindability Index
INDEXSCALE0100HGI B&WNOMINALINDEX50HGI TYPICALCOALS BITUMINOUS=4045HGI

PRB=5055HGI

.8

WaystoImproveFineness
AirFlow
Operateondesignair/coalcurve,periodicallyverified bypropercalibration Improveairdistributioningrindingzone
Rotatingthroat Throatorifice,plugs,inserts

Lower/eliminateunnecessarycontrolbias Readjustmentsforcoalchanges
Newthroatcastings(Differentvanethickness)

IncreaseClassifierSpeed
.9

AveragingPitot TubesforPrimaryAirDifferential
HighSide PressureTap LowSide PressureTap EqualizingLines

Detailofthepitot tubes

PrimaryAirDuct BetweenFan& Mill

l AirF ow

Pitot Tubes
.10

PossiblePitot TubeProblems
Newpitot tubesinstalledbutnotcalibratedortested Pluggedpitot tubes Cracksorholesinthepitot tubes Pitot tubeholeserodedorenlarged Leaksorplugsinthesignaltubingbetweenthepitot tubesandthepressuretransmitters Damsmissingorbroken Damsleftinwhennewpitot tubeswereinstalled

.11

WhatCouldBeWrongWithYourMill?
Primaryairflowissettoohighortoolowforpropermilloperation Primaryairflowissettoohighortoolowforgoodcombustion Primaryairflowmeasurementisincorrect Thecoalbeingburnedisnotwhatthemillwascalibratedtogrind

.12

WhyProperMillCalibrationIsImportant
Primaryairisneededtodrythecoalandtotransport thecoal Onlyuseenoughprimaryairtodryandtransportthecoal Properprimaryairflowhelpsmaintaintheproperbedof coalinthemill Themillisaballbearingwiththecoalbedactingasthegrease

.13

WhatHappensIfWeHaveTooMuchPA?
Coalfinenessisreducedasincreasedcirculationthroughtheclassifier increasesthechanceforlargeparticlestoblowthroughtheclassifier Higherthroatvelocityblowscoaloutofthebedintheringsthusreducing thelubricatingeffectinthegrindingzone Lesscoalbedinthegrindingzonecanresultinrippling,chippingand crackingoftheringsaswellasspalling andunevenwearontheballs Increasedvelocityattheburnercanmaketheflameunstableand increase theLOIandpossiblyNOx emissions

.14

WhatHappensIfWeHaveTooLittlePA?
Wetcoalattheburnermaynotigniteproperlyresultingin increasedslagging andincreasedLOI ReducedPAtemperatureattheburnermaycauseignition issuesresultinginincreasedslagging andincreasedLOI Theflamecouldpullbackintotheburner Couldhavecoaldribbleatlowermillloads

.15

ComparePulverizerPARequirementstoPARequirementsforthe RestoftheCombustionSystem
B&Wcoordinatesthesizeandperformanceoftheburnersandcoal pipingwith pulverizers SomeaftermarketburnersrequiremodificationstothePAflowto optimize combustionandemissions ChangingthecoalpipesizewillaffectminimumPAflowrequirements Pulverizers,coalpipes,andburnerscannotbeseenasseparateentities,as theyareallinterrelated

.16

PerformPrimaryAirCalibrationsProperly
Preparepulverizercontrolcurvebasedonthecoalbeingused CalibratethePA,Dp andMillDp pressuretransmitters Remove,inspect,cleanandleakcheckpitot tubes Isolateallsealair Fillrawcoalchutewithcoalandclosevalveatcoalsilo PerformPADp versusMillDp test;resultingcurvemustbea straightlinepassingthroughtheorigin Performcleanairtests(traverses)withPAflowsintherange expectedduringactualoperation UsemanometertomeasurePADp,MillDp,andPApressure Comparemanometerreadingstocontrolroomreadings Marktestpitot tubeforequalareas
.17

PerformPrimaryAirCalibrationsProperly(cont.)
MeasurePAflowineachcoalpipe CalculatetheKfactorforthepitot tubes Repeattestingat34PAflows AlloftheKfactorshouldbewithin5%oftheaverage ComparePAflowsineachcoalpipe;thisisconsideredto beagoodindicationofthecoalbalancebetweencoal pipes Preparefinalmillcontrolcurvesalsocalled CharacterizationCurvesorDirtyAirCurves

.18

WhatCanChangeYourKFactor?
Newormodifiedburners Newgrindingzoneinmill Significantcoalchange(changesPArange) ModificationstoPAfans(changeshowPAcomesofffan towardpitot tubes) ModificationstothePADucts(changeshowPAcomesoff fantowardpitot tubes)

.19

EffectofPRBonMillOperations
SignificantlyhigherPAtemperaturesrequiredduetohigh moisture inPRB SignificantlyhighervolumeofcoalfeedduetolowerBTUin PRBandlowerbulkdensityofPRB PRBisSticky itplugschutesandhoppersoranyplaceitfalls ontoaledgeorridge PRBlovestoburn itburnsintheboiler,itburnsinthe pulverizers,itburnsinthehoppers,itburnsinthepile,etc.
.20

EffectofPRBonMillOperations(cont.)
BlendsofbituminouscoalandPRBhavespecialproblems Grindingbituminouscoalisliketryingtobreakaboxfull ofmarbleswithasledgehammer GrindingablendofbituminouscoalandPRBisliketrying tobreaktheboxfullofmarbleswiththesamesledge hammeraftersomeonehasmixedinabunchoftennis balls PRBismorefriablethanbituminouscoal,soitwillhavea smallsizedistributioninthebunkers
.21

EffectofPRBonMillOperations(cont.)
Mostbunkersandsilosarehighlyeffectiveparticlesize segregators Thismeansaverageparticlesizeofthecoalwillvaryover abunkerloadingcycle Coalbulkdensitycouldchangedependingonhowsmall andlargeparticlesfittogetherinyourbunker Alsomoisturecontentcouldchangeassmallerparticles withmoresurfacetovolumeratiobringinmoresurface moisture
.22

CurrentB&WRollWheelPulverizerOperatingData
Thefollowingdata(providedbythecustomer)isrequiredbyB&W forusein determiningtheoptimumrotatingthroatportarea: 1.Normalfullloadcoalflowperpulverizer. 2.Normalfullloadairflowperpulverizer. 3.Pulverizerinlet/outletairtemperatureatabovenormalfullloadcoaland airflow. 4.Milldifferentialpressureatnormalfullloadcoalflow. 5.Millinletstaticpressureatnormalfullloadcoalflow (highsideofmilldifferentialpressure. 6.Maximumcoalflowatwhichpulverizerisoperated. 7.Minimumcoalflowatwhichpulverizerisoperated. 8.Numberofcoalpipesinserviceperpulverizer. 9.RawcoalHardgrove grindability. 10.Rawcoaltotal/surfacemoisture. 11.Rawcoalashcontent. 12.Rankoffuel. 13.Isthereasignificantamountofpyrites,rockortrampiron inthecoal? 14.Actualvs.desiredfineness. 15.Whatisthemajorgoalofinstallingrotatingthroatsi.e.;reducemillpressure drop, reducegrindingzoneerosion,improvefineness?

.23

RollWheelPulv.ClassifierAssembly

RawCoal

Classifier Discharge Baffles

.24

PoorFinenessinaRollWheelPulverizer
Holeinclassifiercone Missingflapgate Flapgatestuckopen Lowspringpressure

.25

WaystoImproveRollWheelPulverizerFineness
Classifierlouversection
Outside/insidediameter Vaneangle Vanelength Numberofvanes Dischargecylinderlength Bottomplate(retention/spin)

Classifiercone
TopI.D. Coneangle Conevolume

Classifierdischarge(reduceSeal leakage)
Conicalbaffles Slopeddischargedoors Improveddoors(hingesfitup weighted)
.26

B&WRollWheelPulverizer ImprovementsUpdate
RodPifer
.27

B&WRollWheelPulverizerUpgrades
CastLowPressureDropRotatingThroats Wearesistor Tires Wearesistor LowProfileTires SmoothI.D.grindingsegments SegmentedYokeAirSeal Ceramiclinedswingvalveseats

.28

Wearesistor (Asymmetric)Tires

StandardTire Profile Substantialincreaseinusablewearmaterial comparedtooriginaldesigntires Usewithoriginaldesignstandardprofile grindingsegments Mountsonexistingwheel Nomodificationsrequired Wearesistor Tire Profile

.29

SmoothI.D.GrindingSegmentsforB&WRollWheelPulverizers

.30

CutAwayViewofSegmentedYASinPulverizer

.31

NewSegmentedYokeAirSeal(SplitLineShown)

.32

NewYASInstalledinPulverizer (MatchMarkedSegmentsShown)

.33

WearresistantCeraVAM SwingValvePlateandSeat forRollWheelandELPulverizers

.34

.35