BOILER & CO-GENERATION

HINDALCO INDUSTRIES LIMITED

MAJOR CONTITUENTS

DM PLANT COAL

HANDLIING PLANT

CO-GENERATION

PLANT

ASH ANDLING

PLANT

BOIILER

3

INTRODUCTION TO BOILER

ENCLOSED PRESSURE VESSEL

HEAT GENERATED BY COMBUSTION OF FUEL IS TRANSFERRED TO WATER TO BECOME STEAM

PROCESS: EVAPORATION

STEAM VOLUME INCREASES TO 1,600 TIMES FROM WATER AND PRODUCES TREMENDOUS FORCE

BOILER TO BE EXTREMELY DANGEROUS EQUIPMENT. CARE IS MUST TO AVOID EXPLOSION.

What is a boiler?

COGENERATION PLANT VIEW

20 A

TA

11 A

TA

3.9

ATA

11 A

TA

3.9A

TA

CONDENSER

CONDENSER

5 BAR TO PROCESS

M

~

20 A

TA

~~

~

H.P.HTR

35 MW

6 MW

31.4 MW

5.6 MW

54 ATA COMMON HEADER

43 A

TA H

EA

DE

R

54 ATA COMMON HEADER

To Economiser

From BFP

B#4 150 TPH

Reynolds

Digestion 1, 3 & 4

B#3 140 TPH

B#2 80 TPH

B#1 80 TPH

~

Auxiliary Steam

4 BAR STEAM

6 MW

600/

250

12 Bar steam to Dig-2

7 B

ar H

dr

7 BAR TO PROCESS

250 PSI from Hi-Tech

COGENERATIONPLANT•CO-GENERATION MEANS SIMULTANEOUSLY PRODUCTION OF POWER

& USEFUL THERMAL ENERGY FOR PROCESS FROM THE SAME PRIMARY ENERGY SOURCE. AS PER MINISTRY OF POWER CO- GENERATION IS DEFINED AS ONE WHICH SIMULTANEOUSLY PRODUCES TWO OR MORE FORMS OF USEFUL ENERGY SUCH AS ELECTRIC POWER AND STEAM, ELECTRIC POWER & SHAFT (MECHANICAL) POWER ETC... IT ALSO DEFINES ANY FACILITY THAT USES WASTE INDUSTRIAL HEAT FOR POWER GENERATION BY SUPPLEMENTING HEAT, NOT MORE THAN 50%, FROM ANY FOSSIL FUEL.• AT HINDALCO WE ARE HAVING THE COGENERATION PLANT IN WHICH WE USE THE STEAM FOR THE PROCESS REQUIREMENT AS WELL AS POWER GENERATION

WHAT IS A BOILER

ANY CLOSED VESSEL EXCEEDING 22.75 LITRES IN CAPACITY WHICH IS USED EXCLUSIVELY FOR GENERATING STEAM UNDER PRESSURE INCLUDES ANY MOUNTING AND OTHER FITTING ATTACHED TO SUCH VESSEL WHICH IS FULLY OR PARTIALLY UNDER PRESSURE WHEN SHUTOFF

AUXILIARIES OF BOILER

FANSINDUCED

DRAFT FAN

PRIMARY AIR FAN

FORCED DRAUGHT

FAN

ID FAN

•THE FUNCTION OF THIS FAN IS TO MAINTAIN THE DRAFT IN THE FURNACE AND CARAY OUT FLUE GAS OF THE FURNACE AND MAINTAIN THE NEGATIVE VALUE OF PRESSURE INSIDE THE FURNACE

PA FAN

•THE FUNCTION OF THIS FAN IS TO HEAT AND CARRY COAL FROM MILL TO THE FURNACE ( PULVERISHED COAL).

FD FAN

•THE FAN IS USED FOR THE PURPOSE OF SUPPLYING EXCESS AIR IN THE FURNACE FOR COMPLETE COMBUSTION OF COAL

AUXILIARIES OF BOILER• The function of air preheater is to heat the incoming air from

the Primary air fan which is supplied to the mills, Basically we are using this air as the medium for heating and conveying the Pulverized coal. The air preheater is located in the second pass of the Boiler and it gains its heat by the flue gases and gives the heat to the incoming air. AIR

PREHEATER

• The Economizer is the located in the second pass of the Boiler its function is to utilize the heat of flue gases coming out of the first pass of the Boiler which have done their work of producing steam from the Boiler. The economizer utilizes this heat of Flue gases which would otherwise be wasted to the atmosphere resulting in dry flue gas loss and reducing the efficiency of the Boiler.

ECONOMISER

AUXILIARIES OF BOILER • The function of the mill is to grind the coal in

the required size, like the size of coal required in the Pulverized fuel fired Boilers is of 75 microns so to achieve that size the mills are used. The mills used in the cogeneration plant are of Ball mill and Bowl mill type.

MILL

• The function of super heater is to superheat the Dry saturated steam coming from the drum and convert it into the superheated from so that chances of moisture is totally eliminated and the Enthalpy of steam is increased.

SUPERHEATERS

AUXILIARIES OF BOILER

• The function of the Electrostatic Precipitator is to collect the ash coming out of the Boiler and send it to the ash silo from where it is further utilized as per requirement. The ESP works on the principle of Corona where the Ash particles are charged by Direct Current and further collected at the collecting electrodes and than removed with the help of rappers and collected in the ash silos.ESP

12

DETAILS OF BOILERS

BOILERS TYPE CAPACITY PR.

KG/CM2TEMP.

0 C

YEAR OF COMMISSI

ONINGMAKE

BOILER # 1 FRONT FIRING

(PF)80 (TPH) 52.5 450 1986 WIL PUNE

BOILER # 2 AFBC 80 (TPH) 52.5 450 1989BHEL, TRICHI

BOILER # 3TANGENTIAL FIRING (PF)

140 (TPH) 111 535 1996BHEL, TRICHI

BOILER # 4TANGENTIAL FIRING (PF)

150 (TPH) 111 535 2004BHEL, TRICHI

STEAM GENERATION PER HOUR = 450 MT

STEAM RECEIVED FROM HI-TECH = 25-35 MT / HR

13

DM water

Deaerator

BFP

Coal to feeders by Dozer

Coal Conveyors

Rotory Coal Feeders

Furnace

Coal Transporting Line

Steam Generation

Flue Gas to ESP

PA Fan

FD Fan

Economiser

Water Circuit

Coal Yard

Coal sizing circuit for

-6mm size coalCoal

Bunkers

ID Fan

Ash Recycling feeder-2

No.

Steam to Power Plant / Process

Exchange of Heat Energy

Feeder Running

YES

AshHopper

NOAsh drai

n

Ash Recycling feeder-2

No.

Process Flow of Boiler#2

FLUIDISED BED COMBUSTION BOILER

15

AFBC BOILER

•AFBC – ATMOSPHERIC FLUIDIZED BED COMBUSTION

•DEFINITIONWHEN AIR OR GAS IS PASSED THROUGH AN INERT BED OF SOLID PARTICLE SUCH AS SAND OR CRUSHED REFRACTORY, THE AIR STARTS BUBBLING THROUGH THE BED AND PARTICLE ATTAIN A STATE OF HIGH TURBULENCE.UNDER SUCH CONDITIONS, THE BED

ASSUMES THE APPEARANCE OF A FLUID AND EXHIBITS THE PROPERTIES ASSOCIATED WITH A FLUID AND HENCE THE NAME AFBC

16

FBC MECHANISM

IF THE BED MATERIAL IN FLUIDIZED STATE IS HEATED TO THE IGNITION TEMPERATURE OF THE FUEL AND

THE FUEL IS INJECTED CONTINUOUSLY INTO THE BED, THE FUEL WILL BURN

RAPIDLY AND BED ATTAINS A UNIFORM TEMPERATURE DUE TO

EFFECTIVE MIXING.

17

AFBC BOILER - ADVANTAGE

• FLEXIBLE IN THEIR ABILITY TO BURN A WIDE RANGE OF FUEL.

• DOES NOT REQUIRE OIL SUPPORT FOR START UP OR LOW LOAD

STABILIZATION.

• BY ADDING OF LIMESTONE IN THE BED STRINGENT SOX EMISSION

CONTROL IS POSSIBLE WITHOUT EXPENSING DOWN STREAM

SCRUBBER EQUIPMENT

• AUXILIARY POWER CONSUMPTION IS LOW.

• BETTER LOAD RESPONSE AND CAN BE VARIED FROM 20% TO 100% OF

NCR.

• LESS INITIAL COST.

• EASY IN OPERATION.

• C & I REQUIREMENT FOR FBC ARE MINIMAL. NO BMS REQUIRED

18

AFBC BOILER - DISADVANTAGE

• SUITABLE FOR LOW AND MEDIUM CAPACITY ONLY.

• MORE MAINTENANCE COST DUE TO HIGH

EROSION OF TUBES.

• LOWER EFFICIENCY.

• MORE EFFORTS REQUIRED WHEN IT IS INITIALLY

START UP WITH CHARCOAL.

19

FUEL FEEDING SYSTEM

•Fuel is evenly distributed by judicious location of feed points for

burning most of the volatiles and carbon within the bed and to

avoid localized fuel concentration

Comp-1Comp-2Comp-3Comp-4

Coal feed points

Recycle ash feed points

Distributor plates

20

AIR DISTRIBUTION

•PROPER AIR DISTRIBUTOR IS REQUIRED TO ENSURE UNIFORM

DISTRIBUTION OF AIR ACROSS BED CROSS SECTION

Comp-1Comp-2Comp-3Comp-4

Nozzles are provided across the bed for proper air distribution

21

BED TEMPERATURE & HEIGHT

•BED TEMPERATURE: - FBC NORMALLY

OPERATES AT A TEMPERATURE RANGE

750-950º C FOR COAL

• BED HEIGHT: - DETERMINED BY THE NEED TO

SUBMERGE HEAT EXCHANGER TUBES AND IN CASE OF

HIGH SULPHUR COAL THE VOLUME REQUIREMENT FOR

EFFECTIVE SULPHUR CAPTURE

FOR MOST OF THE INDIAN FUELS A SHALLOW BED

LESS THAN 1000 MM IS ADEQUATE.

22

BED TEMPERATURE & HEIGHT

Water Head

er

Air from FD Fan

Coal Transporting Line

Primary Air

Bed material in Fluidization state

24

BLOCK DIAGRAM OF AFBC BOILER

NRV

PA FAN

ID Fans

FD FAN

BFP

DEAERATOR

FEED PUMP

PSH

ECO

APH

ESP

BFP (N)

BFP (S)

Final Steam to Process

DSHP

DSHP

To Common Header

FD FAN

FD FAN

PA FAN

PA FAN

SSH

134 2

25

TECHNICAL DATA

SN PARAMETER UNIT CAPACITY

1 Heating Surface M² 3426.9

2 Steam Flow TPH 80

3 Steam Pressure Kg/Cm²

52.5

4 Steam Temperature Deg C 450±5

5 Feed Water Temp. Deg C 105

6 Fluidized Air Temp Deg C 130

7 Boiler Efficiency % 82±1.5

Coal Size: -(-) 6 mm to Furnace with maximum 20% fines

26

Boiler Flue gas

Steam Output

Efficiency = 100 – (1+2+3+4+5+6+7+8)

(by In Direct Method)

Air

Fuel Input, 100%

1. Dry Flue gas loss2. H2 loss3. Moisture in fuel4. Moisture in air5. CO loss

7. Fly ash loss

6. Surface loss

8. Bottom ash loss

WHAT ARE THE LOSSES THAT OCCUR IN A BOILER?

27

INTERMITTENT BLOWDOWN

• THE INTERMITTENT BLOWN DOWN IS GIVEN BY MANUALLY OPERATING A VALVE FITTED TO DISCHARGE PIPE AT THE LOWEST POINT OF BOILER SHELL TO REDUCE PARAMETERS (TDS OR CONDUCTIVITY, PH, SILICA ETC) WITHIN PRESCRIBED LIMITS SO THAT STEAM QUALITY IS NOT LIKELY TO BE AFFECTED

• TDS LEVEL KEEPS VARYING• FLUCTUATIONS OF THE WATER LEVEL IN

THE BOILER.• SUBSTANTIAL AMOUNT OF HEAT ENERGY IS

LOST WITH INTERMITTENT BLOW DOWN.

28

•WHEN WATER EVAPORATES

•DISSOLVED SOLIDS GETS CONCENTRATED

•SOLIDS PRECIPITATES

•COATING OF TUBES

•REDUCES THE HEAT TRANSFER RATE

Why Boiler Blow Down ?

PULVERIZED FIRE BOILER SKETCH

30

PULVERIZED FUEL BOILER

Tangential firing

Coal is pulverised to a fine powder, so that less than 2% is +300 microns, and 70-75% is below 75 microns.Coal is blown with part of the combustion air into the boiler plant through a series of burner nozzles.

• Combustion takes place at temperatures from 1300-1700°C

• Particle residence time in the boiler is typically 2-5 seconds

• One of the most popular system for firing pulverized coal is the tangential firing using four burners corner to corner to create a fire ball at the center of the furnace.

31

ADVANTAGES ITS ABILITY TO BURN ALL RANKS OF COAL FROM

ANTHRACITIC TO LIGNITE, AND IT PERMITS COMBINATION FIRING (I.E., CAN USE COAL, OIL AND GAS IN SAME BURNER). BECAUSE OF THESE ADVANTAGES, THERE IS WIDESPREAD USE OF PULVERIZED COAL FURNACES.

DISADVANTAGES HIGH POWER DEMAND FOR PULVERIZING REQUIRES MORE MAINTENANCE, FLY ASH EROSION

AND POLLUTION COMPLICATE UNIT OPERATION.

Pulverized Fuel Boiler

32

PULVERIZEDFUELFIRING

33

FUELS SYSTEM IN PF BOILER#1

BALL MILL:-• IT IS FRONT WALL FIRED PULVERIZED FUEL BOILER

HAVING FOUR BURNERS ON FRONT WALL.

• BOILER NO. 1 IS PULVERIZED FUEL BOILERS.

• OIL GUNS IS PROVIDED FOR START UP AND SUPPORT AT

TWO LEVELS.

• MINUS 20 MM SIZE COAL IS FED TO THE MILL THROUGH

THE TWO NUMBER VOLUMETRIC COAL FEEDERS.

AS THE MILL ROTATES, THE COAL IN THE MILL IS PULVERISED

BY THE CRUSHING AND GRINDING ACTION OF CASCADING

STEEL BALLS. PREHEATED AIR WHICH COMES FROM PRIMARY

AIR FAN, AND FUEL MIXTURE, AFTER PASSING THROUGH THE

CLASSIFIERS, ENTERS THE COAL CONDUITS AND PASSES ON

TO THE BURNERS. THE OUTPUT OF THE MILL SYSTEM FOR A

GIVEN FUEL DEPENDS ONLY UPON THE AIR FLOW THROUGH

THE PULVERISER. A CONSTANT SPEED MOTOR THROUGH A

GEAR REDUCTION SYSTEM DRIVES THE MILL.

34

BALL MILL OF PF BOILER#1

35

FUELS SYSTEM IN PF BOILER#3 & 4

BOILER NO. 3 & 4 IS TANGENTIAL FIRED PULVERIZED FUEL BOILER HAVING FOUR ELEVATION BURNERS.

IN EACH ELEVATION FOUR COAL BURNER ARE AVAILABLE.

FOUR NUMBER BOWL MILLS ARE THERE TO CRUSH THE 20 MM SIZE COAL. OUT OF THESE FOUR MILLS, THREE MILLS SHOULD BE IN SERVICE FOR FULL STEAM LOAD.

BOWL AND ROLLERS ARRANGEMENTS ARE THERE TO CRUSH THE 20-MM SIZE COAL INSIDE THE MILL. HOT AIR FROM AIR PREHEATERS SUCKED BY THE EXHAUSTER OF RUNNING BOWL MILL CARRIES PULVERIZED COAL ON TO THE BURNERS AFTER PASSING THROUGH THE CLASSIFIERS.

36

QUALITY OF COAL

Coal Feed SizeBOILER #1, 3 & 4: 100% (-) 20 MM TO MILL

70% (-) 200 MESH TO FURNACE

BOILER#2 : (-) 6 MM WITH 20% FINES TO FURNACE

MOISTUREVOLATILEMATTER ASH

FIXEDCARBON

CALORIFICVALUE

10%-16% 21%-26% 35%-38% 25%-30%2900-3500

KCAL/KG

Proximate Analysis Values

37

. REDUCE STACK TEMPERATURE22O C REDUCTION IN FLUE GAS TEMPERATURE INCREASES BOILER EFFICIENCY BY 1%

. COMBUSTION AIR PREHEATING

. FEED WATER PREHEATING USING ECONOMIZER6OC RAISE IN FEED WATER TEMPERATURE, BY ECONOMISER/CONDENSATE RECOVERY, CORRESPONDS TO A 1% SAVING IN FUEL CONSUMPTION

IN ORDER TO IMPROVE THERMAL EFFICIENCY BY 1%, THE COMBUSTION AIR TEMP. MUST BE RAISED BY 20 DEG C.

ENERGY CONSERVATION OPPORTUNITIES IN BOILER

. INCOMPLETE COMBUSTION

38

Energy Conservation Opportunities in Boiler

. CONTROL EXCESS AIRFor every 1% reduction in excess air ,0.6% rise in efficiency.

. RADIATION AND CONVECTION HEAT LOSS. AUTOMATIC BLOWDOWN CONTROL. REDUCTION OF SCALING AND SOOT LOSSES. REDUCTION OF BOILER STEAM PRESSURE

Performance of a Boiler

hg -the enthalpy of saturated steam in kcal/kg of steam

hf -the enthalpy of feed water in kcal/kg of water

Boiler Efficiency: Direct Method

Boiler efficiency () = Heat output

Heat inputx 100 Q sx (hg – hf)

Q x GCVx 100=

PARAMETERS TO BE MONITORED: - QUANTITY OF STEAM GENERATED PER HOUR (QS) IN KG/HR - QUANTITY OF FUEL USED PER HOUR (Q) IN KG/HR- THE WORKING PRESSURE (IN KG/CM2(G)) AND SUPERHEAT

TEMPERATURE (OC), IF ANY - THE TEMPERATURE OF FEED WATER (OC) - TYPE OF FUEL AND GROSS CALORIFIC VALUE OF THE FUEL

(GCV) IN KCAL/KG OF FUEL

DM PLANT

THE WATER TO BE FEED IN BOILER FOR STEAM GENERATION MUST BE DEMINERALISED AS PER SHOULD NOT CONTAIN ANY DISSOLVED SOLID SUCH AS SILICA OR CHLORIDES AND CARBONATES WHICH RESULTS IN SLUDEFE FORMATION AND SCALE FORMATION IN THE BOILER RESULTING IN LOW EFFICIENCY OF BOILER ,LOW RATE OF STEAM GENERATION AND WASTAGE AND MORE CONSUMPTION OF FUEL ACCOMPANING WITH CORROSION OF INER BODY SURFACE OR CAN SAY METAL OF BOILER BODY .

SO FOR THIS PURPOSE WATER HAS TO BE TREATED FIRST AND SHOULD MAINTAIN TDS(TOTAL DISSOLVED SAOLID)AS LOW AS POSSIBLE BY PROPER TREATMENT . 

DM PLANT PUMP PUMP AIR BLOWER PUMP FLOW CHART OF D. M. PLANT

CW TANK

DYNA- -SAND FILTER

M G F

A C F

S A C DEGASSED

WATER TANK

S B A

COLD DM TANK

F W TANK

DEMINERALIZATION OF WATER

• THE PROCESS OF DEMINERALIZATION RESULTS IN REMOVAL OF MINERALS FROM WATER,. CLEAR WATER IS RECEIVED FROM CLEAR WATER TANK AND THE MONITORING OF PH (9.7-10.2) AND CONDUCTIVITY (BELOW 150 MICRO SIEMENS/CM) ON DAILY BASIS IS MADE.

DYNA SAND FILTER

• SINGLE FILTER OF SAND SIZE 0.9 MM .ITS BASIC FUNCTION IS TURBIDITY REMOVAL, INLET TURBIDITY TO THE FILTER IS 200PPM AND OUTLET TURBIDITY IS LESS THAN 5 PPM ,ALUM DOSING IS ALSO DONE IN THIS FILTER.

MULTI GRATE FILTER

•THIS IS USED FOR THE REMOVAL OF TURBIDITY THE INLET TURBIDITY IS 40 PPM AND OUTLET TURBIDITY LESS THAN 5 PPM AT PRESENT WE ARE GETTING (0-1) NTU.

ACTIVATED CARBON FILTER•THIS IS USED TO ABSORB EXCESS CHLORINE, REMOVAL OF

ORGANIC MATTER AND OIL & GREASE IF ANY. AND CHARCOAL IS USED AS ACTIVATED CARBON IN THE ACTIVATED CARBON FILTER.

STRONG ACID CATION

•THE STRONG ACID CATION RESIN EXCHANGES ALL CATION IN WATER, THE CATION ASSOCIATED WITH ALKALINITY OR THOSE COMBINED AS NEUTRAL SALTS ALL ARE REMOVED BY SAC RESIN. I T HAS A GREATER AFFINITY FOR DIVALENT ION THAN THE MONOVALENT ION AS A RESULT SELECTIVITY OF CA AND MG IS MORE THAN FOR NA CONSEQUENTLY THE FRONT PORTIONS OF THE RESIN BED ARE PREDOMINANT WITH CA & MG, WHILE NA GOES TO THE TAIL SECTION OF THE RESIN BED AND SO THE NA ION SLIP OUT OF CATION EXCHANGER DUE TO REGENERATIVE EFFECT OF FREE MINERAL ACID

DEGASSER

•IT IS USED FOR CARBON DIOXIDE REMOVAL . CARBONIC ACID GENERATED IN SAC UNIT IS DECOMPOSED IN WATER+ CARBON DIOXIDE AND IT ESCAPES OUT FROM THE TOP OF DEGASSER BY DEGASSER BLOWER , MAXIMUM 6 PPM OF CO2 IS ALLOWED AFTER DEGASSER UNIT.

STRONG BASE ANION•SBA RESIN HAS GREATER AFFINITY FOR

IONIC SPECIES, SULFATE AND CHLORIDE THAN FOR THE MOLECULAR CARBON DIOXIDE AND SILICA AND HIGHER SELECTIVITY FOR SULFATE ION THAN CHLORIDE ION. AGAIN THERE IS DISTRIBUTION OF CONTAMINANTS OVER THE RESIN BED WITH FRONT LAYER HIGH IN SULFATE FOLLOWED BY CHLORIDE AND CARBON DIOXIDE AND THE SILICA AT TAIL END OF THE BED.

MIXED BED

•THE MIXED BED DEMINERALIZATION PROCESS CONSISTS OF SAC AND SBA RESIN INTIMATELY MIXED TO BRING ABOUT THE DEMINERALIZATION OF WATER, IN EFFECT IT IS MULTIPLE AND RANDOM TWO BED DEMINERALIZATION PAIRS RESULTING IN VERY HIGH QUALITY OF DM WATER . HERE THE LEAKAGE OF IONS CAUSED BY THE REGENERATING EFFECT OF FMA OR OF NAOH FORMED IN THE EXCHANGING PROCESS IS ABSENT ,THIS IS BECAUSE FMA GENERATED BY SAC RESIN IS EXCHANGED BY NEIGHBORING SBA RESIN LIKE WISE NAOH GENERATED BY SBA RESIN IS EXCHANGED BY ADJACENT SAC RESIN .CATION RESIN IS HEAVIER THAN THE SBA RESIN SO CATION FORMS THE DOWN LAYER . THE PARAMETERS AT THE OUTPUT ARE PH-6 TO7,CONDUCTIVITY 2 MICRO SIEMENS/CM, SILICA 0.02MG/LTR.

COAL HANDLING PLANT

coal yard

_20mm__2o_2o

BOILER # 1 & 2 BUNKER FLOORBunker

Boiler # 1 Bunker

Boiler # 2

BunkerBoiler # 3

Tripper

Tripper Conveyor

BOILER # 3 BUNKER FLOOR

TripperTrolley

Tripper Conveyor

Conveyor No. 64

Reciprocating Feeder 1or 2

Reclain Conveyor BC - 11831

To Old Circuit #1,#3 To Old Circuit # 2

Vibro Feeder Vibro Feeder

Impactor '+ / -' 6 mm'

Vibrating Screen

Impactor

-20mm Vibro Feeder

Vibrating Screen

'- 6 mm'Coal

'+6 mm' Coal

'+20 mm' Coal

'Buc

ket

Ele

vato

r

Daybin ConveyorBC - 33830

Conveyor - 70

Conveyor - 69

Conveyor - 65

Cross Conveyor

NEW COAL CIRCUIT - FLOW CHART (COAL PLANT)

Triveni / P.K.Sharma/ Sheet 1

'- 20 mm' Coal

COAL PLANT OPERATION

•COAL IS UNLOADING FROM WAGON TIPPLER IN TWO SIZES I E: - 01. +25 MM AND –75 MM (ABOVE 25MM AND BELOW 75 MM) 02. –25 MM AND + 75MM (BELOW 25MM AND ABOVE 75MM)

• AFTER UNLOADING OF COAL WE FED THE DIFFERENT SIZE COAL IN DIFFERENT BOILERS. WE HAVE FOUR BOILERS. THREE ARE PF AND ONE IS FBC. IN PF BOILER WE HAVE USE THE COAL BELOW THE 20MM. IN FBC BOILER WE HAVE USE THE COAL BELOW THE 6MM.FOR, WHICH VARIOUS EQUIPMENTS HAVE BEEN INSTALLED IN COAL PLANT AREA.•TO FEED THE COAL IN PF BOILERS (B#1,3 &4) PUSH THE COAL BY DOZERS IN ROTORY FEEDERS GRIZZLY SITUATED IN COAL YARDS. COAL IS COMING FROM RECLAIM CONVEYER TO CONVEYER#64, THEN VIBRATING SCREEN HAVING SIZE OF 20MM THROUGH VIBRO FEEDER. LESS THAT 20 MM COAL HAVE FALLEN THROUGH SCREEN DIRECTLY TO CONVEYER#70 AND OVERSIZE COAL GOING TO CONVEYER#70 THROUGH COAL IMPACTOR HAVING CAPACITY 120 TPH. FINALLY COAL IS GOING TO THE BUNKERS OF BOILER#1,3&4 THROUGH COMVEYER#70, DAYBIN CONVEYER AND TRIPPER CONVEYER.

•TO FEED THE COAL IN FBC BOILER (B#2) PUSH THE COAL BY DOZERS IN ROTARY FEEDERS GRIZZLY SITUATED IN COAL YARDS. COAL IS COMING FROM RECLAIM CONVEYER TO CONVEYER#64, VIBRO FEEDER THEN COAL IMPACTOR (240TPH) TO TWO NUMBERS VIBRATING SCREENS HAVING CAPACITY OF 120 TPH EACH THROUGH TWO VIBRO FEEDERS. COAL HAS FALLEN THROUGH SCREEN DIRECTLY TO CONVEYER#69(SIZE LESS THAT 6MM) AND OVERSIZE COAL (ABOVE 6MM) GOING TO CONVEYER#64 THROUGH BUCKET ELEVATOR HAVING CAPACITY 65 TPH FOR RECRUSHING IN COAL IMPACTOR WITH FRESH COAL. CLOSE COAL CIRCUIT IS RUNNING DURING COAL FEEDING IN B#2. FINALLY COAL IS GOING TO THE BUNKERS THROUGH COMVEYER#70, DAYBIN CONVEYER AND TRIPPER CONVEYER.

CHP FLOW CHART

FLOW DIAGRAM FOR COAL HANDLING PLANT

Through Feeder Through Feeder

YES

NO NO

YES

B#1 & 2 B#3

Wagon Tippler (Crushed to less than 100 mm size)

Newton In Motion Weighbridge for Weigment of wagons

Caol from Collieries Size:- Less than 500mm

100mm to 75mm and less than 25mm size coal collected in & out side the coal shed for Boiler#1 &

3

75mm to 25mm size coal collected in side

the coal shed for Boiler#2

Reclaim Conveyor

Conveyor#64

Vibro Feeder (W) For Boiler#1 & 3(51)

Vibro Feeder (E) For Boiler#2(48)

Boiler#1 & 3 Coal Impactor (100

MT/HR)

-20mm size

Boiler#2 Coal Impactor (240 MT/HR)

-8mm size

BUCKET

ELEVATOR

Bunkers to fill

Conv#65

Vibro fdr#49 Vibro fdr#50

51