Air and Draft System

T K Ray NTPC Limited

rayt3@asme.org
11 October 2011

Need of Draft System

Combustion Air

Boiler

Flue Gases

Air needed for combustion Flue are needed to be evacuated Losses due to flow need to be overcome
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The Three Ts & One S Practice

Technology Stoker Pulverized Cyclone Fluid Bed

Time large Short Short+ Medium

Temperature Medium High V High Low

Turbulence Low Medium High High

Size Big Tiny Medium Medium

Size the Coal and Add the Air !!!

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Coal an organic complex polymer Sequential events

Devolatilization (Pyrolysis)
Heating causes its structure to decompose Weaker chemical bonds break at lower temperatures Stronger ones at higher temperatures Volatile yield can be up to 50%
SEM of a de-volatilizing coal particle

greater than indicated by proximate analysis

11 October 2011 T K Ray NTPC 4

 Burning of volatile matters

Homogeneous gas phase reaction around the particle

Char burning
Heterogeneous combustion Occurs at the char surface and pore surfaces (porosity~0.7; surface area ~100 m2/g) Guided through competing effects of heat and mass transfers to the char surface and chemical reaction
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Char particle at the early stage of burning

Coal Combustion
homogeneous combustion

volatiles coal particle

p-coal, d=30-70m

CO2, H2O,

char
Heating

heterogeneous combustion

CO2, H2O,

De-volatilization

tdevolatile=1-5ms

tvolatiles=50-100ms

tchar=1-2sec t

Temperature, Turbulence, Time and Size

11 October 2011

VM, Fineness, Combustion & Residence Time Vol. combustion intensity, Iv is in the range 150-250 kW/m3. FEGT<IDT For a desired Iv, one can select tr (~ 2 sec) The combustion time, tc (~ 1 sec) <tr by a significant margin. Low VM coal; more fineness required

11 October 2011

T K Ray PMI

Coal particle size distribution

If 1-2% is +50 in BS mesh sieve (300 m), most of this coarse coal will not burn and end up in C in BA It also frequently causes slagging around the burners If -200 mesh (75 m) fineness is poor, results in high C in FA If the coal is not properly ground, the distribution to the burners may not be even Resulting in air-fuel imbalances at one or more burners

11 October 2011

More Details of Pulverized Fuel fired SG

Furnace Wall

Sequence of Energy Exchange from Flue Gas to Steam

FLUE GAS

PLATEN SH RH
ECONOMIZE R

EVAPORATOR

PENDENT SH

COVECTIV E SH

Combustion Losses

C & R losses

Hot Exhaust Gas losses ~4000C

Fuel Power

LTSH Final SH Platen SH Reheater

Economizer

Furnace absorption

Air Heater in Fossil Fired Plant

The rotating cylinder packed with thousands of sq m of specially formed sheets of heat transfer surfaces. As it revolves, heat of FG is absorbed through one half. The accumulated heat is released to the incoming air as the same surfaces pass through other half. The heat transfer cycle is continuous as the surfaces are alternately exposed to the outgoing gas and incoming air.
October 11, 2011 T K Ray PMI NTPC

Air Pre-Heater
An air pre-heater heats the combustion air where it is economically feasible. Reducing the stack gas temperature and increasing the boiler efficiency. The pre-heating helps the following: Igniting the fuel. Improving combustion. Drying the pulverized coal in pulverizer.

How to select a fan

Air or Gas flow -Kg/hr Density (function of temperature and pressure) System, resistance (losses) Major Fans in Boiler Draft System PA Fans FD Fans ID Fans
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Arrangement of Boiler Auxiliaries

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PRIMARY AIR/MILL SEAL AIR SYSTEM

Ambient air is drawn into the primary air ducting by two 50% duty, motor driven axial reaction fans. Air discharging from each fan is divided into two parts, one passes first through a air pre-heater then through a gate into the P.A bus duct. The second goes to the cold air duct. The mix of both is used to carry the pulverized coal to the boiler.
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Components of PA Fan
Suction Bend With volume Measurement instruments Fan housing with Guide Vanes Main Bearings (Anti Friction) Rotor with impeller with adjustable blade with pitch control Guide vane housing with guide vanes Diffuser with pressure measurement instruments
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SECONDARY AIR SYSTEM

Ambient air is drawn into the secondary air system by two 50% duty, motor driven axial reaction forced draft fans with variable pitch control. Air discharging from each fan passes first through a air preheated then through a isolating damper into the secondary air bust duct. The cross over duct extends around to each side of the boiler furnace to form two secondary air to burner ducts. At the sides of the furnace, the ducts split to supply air to two corners. Then split again to supply air to each of nineteen burner/air nozzle elevations in the burner box.
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Burner Box Dampers

Coal/Air Dampers Secondary Air Dampers Oil/Secondary Air Dampers Bottom Tier Secondary Air Damper Over Fire Damper

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Primary and Secondary air System in the Boiler

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Induced Draft System

There are three induced draught fans per boiler, two operating and one standby In 500 MW fans are single-stage, double-inlet centrifugal fans. Principal fan elements of the fan are:
Housing Inlet dampers Rotor with Bearing Shaft Seal
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11 October 2011

ID Fan
The rotor consists of shaft and assembled impeller and runs in two sleeve bearings that are arranged outside of the housing. The impeller consists of a centre disc and two cover discs that are reinforced by forged rings. The bent blades are welded into position between the impeller discs. The blades are protected by screwed - on wear plates. The shaft is of hollow design. The fan shaft has been rated so that max. operating speed is below the critical speed. Impeller and shaft are connected by means of a flange. This screwing is protected by wear plates. The fan housing is sealed by means of two-part labyrinth seals. 11 October 2011 24 Bearings are lubricated with oil.

Other Fans in The System

Ignitor Air Fan: Provide combustion air to the ignitors. Take suction air from the atmosphere and supplies air to the ignitor wind box. Scanner Air Fan: Supplies cooling air to flame scanners. Normally there are two fans taking suction from FD Fan discharge duct. Mill Seal air fan: Seal air fans provide air for the sealing of Mill bearing. Suction is from cold Primary air and pressure is boosted up to maintain the differential pressure
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AIR AND FLUE GAS PATH TYPICAL 500 MW BOILER

TO MILLS

PAPH-A

SCAPH-A PRIMARY

PA FAN -A

ECO BYPASS

TO ESP

SAPH-A

AA205

AA203

SCAPH-A SECOND

AEROFOIL

AA202

AA201 HORIZONTAL S.H ECONOMISER -1 DIVISION PANELETTE S.H ECONOMISER -2 SA HDR AA204 HOT PA HDR FD FAN -B

PLATEN S.H

HOT

COMBUSTION CHAMBER

RE HEATER

ECONOMISER-3

AA204

AA201

SAPH-B

AA205

AA203
SCAPH-B SECOND

AA202 FD FAN-A

AEROFOIL

COLD SEC. AIR COLD PRIM AIR HOT PRIMARY AIR HOT SEC. AIR FLUE GAS PNEUMATICALLY O/P KNIFE EDGE GATE MOTOR O/P LOUVER DAMPER PNEUMATICALLY O/P LOUVER DAMPER

ECO BYPASS BIPLANE DAMPER

SCAPH-B PRIMARY

TO ESP

DIVERTER DAMPER

TO MILLS PA FAN -A

11 October 2011 MOTOR O/P GATE

PAPH-B

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Pressure at key points in air and FG path

250 200 150 100 50
Furnace Pressure

1 2 3 4 5 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14

FD Fan Inlet FD Fan Outlet Airheater Inlet Airheater Outlet Windbox Pressure Furnace Superheater Platen Inlet Reheater Inlet LTSH Inlet Economiser Inlet Airheater Inlet E.P. Inlet I.D. Fan Inlet I.D. Fan Outlet

0 -50

7
-100

8
-150 -200 -250 -300 Points in Boiler

9 10 11 12 13 14

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Thanks

rayt3@asme.org

11 October 2011