COAL DUST INJECTION SYSTEM

• PURPOSE :
To replace costly BF Coke by Pulverised Coal .
• PROCESS :
Raw coal is pulverised in a continuous Ball Mill
and injected in the furnace through lances into
the tuyeres .Transporting medium is nitrogen.
• Raw Coal For CDI
Type : Non Coking Low Ash ; %Ash : 8-10%
%VM : 20 – 30% ; A.M : 1.8 – 2.5%

• Fine Coal For CDI : less than 90 micron size – 80%

• Furnaces having CDI : Blast Furnace No. 4 & 5

 COAL DUST INJECTION SYSTEM
1. PROCESS FLOW DIAGRAM
: F Mill Bag Filter
Reversible Belt
I
Clean
N
Gas
E
C Screw conveyor
RCS RAV ID Fan
O
A CHIMNEY
Raw
Coal
L Fine Coal Silo
Drag Chain
RECIRCULATION VALVE
Conveyor CHIMNEY VALVE
GROUND
HOPPER Stove Flue gas
Steep HGG
Inclined BOOSTER FAN
Belt
Feeder Belt
BALL Distributor
Distributor MILL

FINE COAL FINE COAL

Injection Vessels
FURNACE-4 FURNACE- 5
 2. COMMON FACILITIES

• NITROGEN SUPPLY SYSTEM.

• RAW COAL SYSTEM.
• GRINDING SYTEM.
 RAW COAL SYSTEM
1. GROUND HOPPER : 100 M3
2. CONVEYOR SYSTEM :
BELT LENGTH WIDT CAPACITY SPEED BUCKETS LIFT /
(MM) H (T/HR) ANGLE

FEEDER 11675 1200 60 0.252 ---- -----

S.INCLINED 65292 800 60 1.6 5 / Metre 463665 /

900
REVERSIBLE 6750 800 60 1.25 ---- -----

3. SUSPENDED MAGNET ;
This is hung over the feeder belt at a height of
300 mm to remove magnetic particles. The
magnet is operated by a 3.5 T telpher.
 RAW COAL SYSTEM

4.Interlocks in the conveyors :

i) Zero Speed.
ii) Pull Chord.
iii) Belt Sway.

5. RAW COAL SILO :

Mouth Dia : 6750 mm
Total Height : 18100 mm
Thickness Of Shell : 10 mm
No. Of Inspection Holes :2
Capacity : 350 m3
 Grinding System
• Drag Chain Conveyor (DCC) -:
Raw Coal silo is fed to a drag chain conveyor, which in
turn feeds coal to coal mill. Coal is fed into DCC through
rectangular opening 200 X 1000 size. Feed amount can be
regulated by means of rod gate provided in the transfer
chute.
Coal inlet opening is in the shape of flange which matches
with the flange of raw coal silo . 48 nos. of Dia 16 bolt are
used to bolt the two flanges. The speed of the coal feeder is
proportional to the supplied raw coal mass stream. Raw Coal
from the hopper falls on feed plate which is conveyed to the
bottom plate. From here the coal is discharged into the outlet
chute; which terminates in a flange type opening.
Specification -:
1. Centre to centre distance of sprockets : 680mm
2. Capacity : 8 - 30 TP/Hr
3. Conveyor Speed : 0.1 MPS
 BAG FILTER
SPECIFICATIONS OF BAG FILTER
• Design Pressure : 1500 mm w/c – 500 mm w/c
• Service Temperature : 90 ºC
• Gas Volume : 76800 m3/H
• Total Filter Area : 1030.5 m2
• Dust Load : 312.5 gms/m3
• Compressed N2 : 2.7m3/min, 5-7 bar
 SCREW CONVEYOR

All the dust collecting hoppers of bag filters discharge into

one drag screw or screw conveyor, the drag screw conveys
the coal dust to the center line of the filter.

Main Specifications -:

Screw Dia : 500mm

Screw Pitch : 500mm
Total Length : 7480mm
Screw RPM : 28
Design Capacity : 43 m3/h
 ROTARY AIR LOCK VALVE
This is located just below the screw conveyor. It is used for feeding
coal dust from screw conveyor to fine coal silo. It should seal
against loss of air/gas thus maintain operating pressure in the
system.

Main Specification -:
Material Handled : Fine Coal Dust
Size of particles : <200 µ
Capacity : 24 TPH
Design Pressure : 500 mm w/c
 DIFFERENT INTERLOCKS IN CDI –BF # 4

A> RAW COAL GROUP INTERLOCKS :

1. All related electrical drives such as Belt Feeder,
Magnet, Metal Detector, Steep Inclined Conveyor, Reversible
Conveyor, FV 1007 FV 1009, D.E. Fan, Raw Coal RAV &
Bag Filter Sequential Controller (EV 1004), are electrically
ok. (i.e. No O/L, No Fault F/B, BS & P/Chord ok; ZS in
B/running ok).
Emergency stop switch not in operated condition.
 Raw coal weighing system is healthy.
 Raw coal Inertisation pressure (PISL 1003) is ok.
 Raw Coal Silo coal level (LS 1010) should be ok.
To start Raw Coal group weight in raw coal silo should
be less than 220 tons. It will stop at 240 tons.
 DIFFERENT INTERLOCKS IN CDI –BF # 4
B> GRINDING – GEAR BOX AND HYDRAULIC GROUP :
1. All drives i.e. Oil pump, hydraulic motor for tensioning device are
electrically healthy & heater E 1219 RD is ok.
2. Oil flow to Mill gear box (FSLL 1218) not low, if low trips the system
after 15 sec.
3. Hydraulic unit press. (PSL 1238) is ok. If not, this group will trip
after 30 sec.
4. Oil temperature (TSHH 1214) of Gear Box is normal else it will trip
immediately.
5. Oil level (LS 1234) of hydraulic unit is ok, else trip immediately.
6. Oil temp. (TSH 1231) of hyd. Unit is normal otherwise trip
immediately.
a) Inertisation press. For fine coal silo (PISL 2013), Mill (PISL
1913), Mill bag filter (PISL 1342) & hand valves (PSL 1873) are ok.
b) Instr. Gas press. (PISL 1902) is ok.
c) Water pressure for spray system over HGG bridge (PISL 1953) is
normal.
Hydraulic and Gear box grp. Can be started after fulfilling all the above
conditions. It would trip if any of the above condition other than Sl. No. 7
becomes false.
 DIFFERENT INTERLOCKS IN CDI –BF # 4
C> GRINDING EMERGENCY OFF
1. If Mill outlet temp. (TT 1250) is >120 degree cel.
2. If HGG is in running condition and
a) Oxygen is >12% before mill and after mill bag filter.
b) CO is >1800 ppm before mill and after mill bag filter.
3. Scanner temperature in any of the six points (TS 1325.1) of mill filter
is >110 deg.C.
4. Waste Gas Temperature (TT 1330) before ID fan is >115 deg.C.
D> FINE COAL TRANSPORT INTERLOCKS
1. Electrical drives iz, RAV (M 1309) & screw conv. (M 1306) are healthy.
2. Sequential controller (EV 2004) is healthy.
3. Analyser is ok.
4. N2/Inertisation pressure (PSL 1303 / PISL 1342) for Mill Bag filter is ok.
5. Fine coal silo level (LSH 2052) is ok.
6. Heater on command is available.
7. Grind Emergency off is not there.
Fine coal transport can now be started.
It would trip if any of the above condition other than sl. No. 3,4 & 5
becomes false.
8. After tripping of Mill, Fine coal stop after 30 Minutes.
 DIFFERENT INTERLOCKS IN CDI –BF # 4
E> I.D.FAN INTERLOCKS
1. ID Fan trip time is over.
2. Drives of I.D. Fan and booster fan are healthy.
3. FV 1421, FV 1500, and FV 1501 are electrically ready.
4. Group Fine Coal is on.
5. No Technological fault in breaker at sub-station.
6. Soft starter / bypass system of booster fan is healthy.
7. Grinding Emergency off not operated.
8. Weight in fine coal is less than 430 T.
9. Mill cleaning (reject box) is over.
ID Fan can now be started.
It would trip if any of the above conditions other than
Sl.
No.1, 8 & 9 becomes false.
10. a) ID fan stops after 6 minutes if TCF trips / off.
b) ID fan stops after 5 minutes if Mill trips / off.
 DIFFERENT INTERLOCKS IN CDI –BF # 4
F> I.D.FAN GROUP VALVES.
1. FCV 1425 :- If Rel/ ID Fan is achieved with start command
FCV 1425 will get command to open.
2. FCV 1402 :- ID inlet valve will start getting open as
soon as M1400FB is available.
3 FV 1421 :- Inlet shut off valve of booster fan
would open after 30 sec. Of booster fan starting.
4. PCV 1422 :- It will get command to open after
booster fan has started & FV 1421 open command is
available.
5. FCV 1410 :- It would get command to open as
soon as FCV 1402 has opened more than 10% &
Rel_ID Fan is available (Chimney valve).
6. FCV 1408 :- After starting of ID Fan, FV-1408 will
get command to open (Recirculation valve).
F> I.D.FAN GROUP VALVES.
1. Group ID Fan should be running.
2. Durinmg starting
a. Mill should be in stopped condition.
b. Waste gas flow at ID Fan should be more than 40,000
NM3/hour.
c. FCV 1410 should have got an open command.
d. CO should be <1000 ppm at all the three points.
e. O2 should be <10% at all the three points.
3. CA Fan motor should be in ready condition.
4. Motor of TCF should be healthy.
5. Both valves FV 1915 & FV 1917 are healthy.
6. Grid emergency off is not there.
7. HGG will start after all the above conditions are met and while
running BR-1 & BR-2 would show flames burning.
8. HGG would trip if
a. Any of the above condition other than sl. No. 2 is not true.
b. If the flame of both the burners goes off.
c. V/F has tripped / off.
If the CO PPM >1800 & O2 % >12%
 HGG INTERLOCKS
1. Group ID Fan should be running.
2. Durinmg starting
a. Mill should be in stopped condition.
b. Waste gas flow at ID Fan should be > 40,000 NM3/hour.
c. FCV 1410 should have got an open command.
d. CO should be <1000 ppm at all the three points.
e. O2 should be <10% at all the three points.
3. CA Fan motor should be in ready condition.
4. Motor of TCF should be healthy.
5. Both valves FV 1915 & FV 1917 are healthy.
6. Grid emergency off is not there.
7. HGG will start after all the above conditions are met and
while running BR-1 & BR-2 would show flames burning.
8. HGG would trip if
a. Any of the above condition other than sl. No. 2 is not true.
b. If the flame of both the burners goes off.
c. V/F has tripped / off.
d. If the CO PPM >1800 & O2
 H> MIL INTERLOCKS
1. Drives of Mill & hyd. Unit are healthy and heater of Hyd. Unit is ok.
2. Hydraulic System
a) Oil press. For mill gear box (PSIL 1216) is ok.
a) Oil flow to mill gear box (FSLL 1218) not low.
b) Oil temp. (TSHH 1214) of Gear box is <60 OC and >10 OC (TT 1204).
c) Hyd. Unit oil leel (LS 1234) is not low.
d) Hyd. Units oil temp. (TSH 1231) is not high.
3. Gear box hyd. Group are in running condition.
4. Grind emergency off is not there.
5. Group ID Fan is on.
6. Group fine coal transport is on.
7. During starting of the mill
a) Group HGG is in running condition.
b) Mill outlet temp. is > 90 OC.
c) Mill trip time is over (30 Minutes).
8. Mill can now be started.
9. Mill would trip.
a) If all the above condition other than sl. No. 5 is not healthy.
b) After 6 minutes of HGG tripping.
c) After 6 minutes of V/F tripping.
 I> TROUGH CHAIN FEEDER INTERLOCKS
1. 1. TCF drives is ok. (i.e. Motor and valves FV 1917 & F 1915 are
healthy).
2. Group Fine coal is on.
3. Group ID Fan is on.
4. Temp. of mill is >= 90OC.
5. Mill is running.
6. Weight of raw coal silo is > 50 tons.
7. Group HGG is on.
8. Grinding emergency off is not there.
9. Waste gas flow at ID fan is >42000 NM3/Hr.
10. Diff. Press. Across mill is <75 bar.
11. Diff. Press. Across Mill bag filter is <15 bar.
12. Analyser is healthy.
13. Reject gate is open.
14. Temp. after Mill bag filter should not be >5 OC of mill outlet temp.
15. Bag filter level of LHS 1314, 1315 & 1316 should not be high.
16. Fine coal silo level is below 490 tons.
17. TCF can now be started if all the above conditions are met.
18. TCF would stop / tripa.
--- If the temp. across Mill is reduced to <80OC.
--- If any of the above condition except sl. No. 4 is not true.
 J> INJECTION SYSTEM INTERLOCKS IN BF-4 CDI

1. All related drives such as Agitator, Vibrator, Hydraulic unit of

injection, Electrical and other control valves are ready.
2. Following conditions are required to be fulfilled for hydraulic unit of
injection system.
a. Oil level (LSL 2600) is ok.
b. Oil temp. (TSH 2601) is not high.
c. Oil press. Not below 70 bar.
(Motor starts at or below 80 bar and stops at 90 bar. There are two nos.
of oil pump motors get started alternately at 4 hrs. interval).
3. “GENERAL ON’“ CONDITIONS:-
a. Instr. Gas Press. / Impulse line Press. (PSL 2502) is ok.
b. Weighing system of vessel – 1 or vessel – 2 are ok.
c. Both the vessel should not be in stop mode at a time.
d. General on Alarms ok (i.e. General off PB not operated from control
desk or from operator’s station).
e. Fine coal group’s seq. controller (EV 2004) ON Command is there.
f. Buffer tank press. 8.8 bar.
 K> INECTION START CONDITIONS

1. 1. Filling for the related vessel should be over.

2. Vessel press. Should be greater than the set
point of PIC 2121 (Normal press. Line) (PIT 2116 /
2216 ) > [S.P. PIC 2121) – 0.5]
3. Weight of vessel >minimum weight (0.8/1 Ton).
4. General on is there.
5. VI/V2 not in stop mode.
6. Related vessel should not be in vent mode.
7. Receiving Tank press. >9 bar.
 L> INJECTION STOP CAUSES:-

1. 1. By control desk push button.

2. By operator’s station.
3. Special stop from LCP – 1 or LCP – 2 or LCP-3.
4. PIT 2188 < (Inject vessel press. – 1.0 bar).
5. PIT 2140 < Inject vessel press.
6. No. of healthy lances <Minimum no. of healthy
lances (8/10).
7. Low Cold Blast flow (<2200 NM3/Min)
8. Conveying flow (FIT 2182) is <141 NM3/Hr. for
minimum 20 sec.
9. If both recirculation (HV 2191) and conveying
(HV 2190) lines are open or closed
 BF-5 CDI
BASIS FOR SYSTEM DESIGN :
S.N PARAMETERS DESIGN
VALUE
1. HOT METAL PRODUCTION (T / DAY) 3500
2. NUMBER OF TUYERES ( FOR INJECTION ) 20
3. HOT BLAST PRESSURE [MPa (MAX)] 0.27
4. HOT BLAST TEMPERATURE (0C) 1100
5. CDI RATE Kg/THM
• WITHOUT O2 ENRICHMENT 80
• WITH O2 ENRICHMENT ( GUARANTEED) 100
• DESIGN 150
 BF-5 CDI
COAL ANALYSIS AS PER DESIGN :
S.N PARAMETERS DESIGN VALUE
1. Carbon, % 60-70
2. Sulphur, % 0.4-0.65
3. Phosphorous, % 0.025-0.075
4. Hydrogen, % 4.5-5.5
5. Oxygen, % 3.8-7.0
6. Nitrogen, % 1.8-2.5
7. Volatile Matter, % 20-35
8. Ash, % 9-12
9. Coal Dust Moisture, % < 1.5
10. Coal Dust Fineness 80%<90µm
11. Hard Grove Index 50-90
12. Calorific value, kCal/kg 6800
 BF-5 CDI
COAL ANALYSIS AS PER DESIGN :
S.N PARAMETERS DESIGN VALUE
1. Carbon, % 60-70
2. Sulphur, % 0.4-0.65
3. Phosphorous, % 0.025-0.075
4. Hydrogen, % 4.5-5.5
5. Oxygen, % 3.8-7.0
6. Nitrogen, % 1.8-2.5
7. Volatile Matter, % 20-35
8. Ash, % 9-12
9. Coal Dust Moisture, % < 1.5
10. Coal Dust Fineness 80%<90µm
11. Hard Grove Index 50-90
12. Calorific value, kCal/kg 6800
 4. Difference Between CDI in BF- 4 & 5
S.No BF-4 BF-5
1 Vessel Volume : 15 M3 Feed Tank Volume : 22M3
2 Max. Wt of fine coal in a Max. Wt of fine coal in a feed
vessel : 7.5 T tank :10.0 T
3 Maximum Rated Capacity Maximum Rated Capacity
: 18.75 T/Hr : 22 T/Hr
4 Injection rate is controlled by Injection rate is controlled by
metering valve Pressure Algorithm
Injection @ 4.0T/Hr is possible Injection below 5.5T/Hr is not
possible
5 Dense Phase distribution Semi Dense Phase distribution
6 Pressure requirement in the Pressure requirement in the
vessel for injection is more vessel for same rate of
: 6.5 to 13.5 bar (max) injection is less
: 3.5 to 9.5 bar (max)
7 Transport nitrogen Transport nitrogen
requirement is much less requirement is much more.
8 No control (off & on) ”granular Control system (off & on)
flow alarm “of each individual exists for ”granular flow alarm
line “in individual line
 Difference Between CDI in BF- 4 & 5
S.No BF-4
9 The provision of putting
lances in “Local Mode” from
“Auto” does not exist in HMI.
10 “Injection On” is indicated by
red lamp in the mimic panels
at CDI & BF-4 Control Room
11 Total N2 requirement is much
less : 500 -900 NM3/Hr
12 Dia of the injection line : 82m
13 Main Injection pipe is lined
with wear resistant lining
inside in the bends and first
straight piece behind the bend.
14 Lances are cooled through
coal line when injection is off. nitrogen purge line when
15 In case of power failure, coal
valves remain open and N2
valves closed.
BF-5
Any lance can be put in “Local
Mode” from “Auto” through
HMI.
“Injection On” is indicated by
green lamp in HMI to mimic
panels in the system
Total N2requirement is much
more : 1400 -2500 NM3/Hr
Dia of the injection line : 100-
124 M
There is no such lining inside
the main injection pipe line.
Lances are cooled through
injection is off.
In case of power failure, N2
valves open and coal valves
close.
 Difference Between CDI in BF- 4 & 5
S.No BF-4 BF-5
16 Injection vessel in BF-4, For any amount of fine coal
does not depressurizes, if in the vessel, the vessel
injection trips when wt. of depressurizes and goes “out
coal > 4.0T cycle” if injection trips.
17 There is no system of Everytime, the injection is
“cleaning” of the coal lines started, cleaning of N2 is done
when injection is started for 3 mts. through coal line.
18 Quick pressurization is At lower injection rate say 5.5
must everytime the vessel is T/Hr, the preparation time is
made ready for injection min. and the pressurization is
done through Fludizin line
19 Smaller lance dia : 18mm Bigger lance dia :33mm
20 Female couplings are Male & Female couplings are
provided in either side of provided in the hoses.
injection hoses
21 Provision of Back Blow No provision of Back Blow
22 Amount of N2during cooling Cannot be known since there
of lances can be known is no flow meter (FET) in the
since cooling is done purging line.
through Coal line.
 Difference Between CDI in BF- 4 & 5
S. BF-4
N
23. No fluffing is required in the coal
line . Nothing remains in the coal
line after injection stops.
24. Injection Start Conditions :
• “Emergency” Flag On.
• One Vessel must be “ON”.
• “General” Flag ON.
• Vessel not in vent mode.
• Vessel filling is over.
• Vessel wt.> Vessel Min. wt. > 0.8
ton
• Vessel pressurized to the set
point.
• No. of healthy Lance > Set Min.
BF-5
Fluffing is required in the coal
line . Coal in ultra dense
phase remains in the coal line
between the valves under the
feed tanks, after injection
stops.
Injection Start Conditions :
• “Normal Stop” Healthy.
• “Emergency Stop” Healthy
• One feed tank in “Holding”.
• Fine coal Silo Wt.> 15 Tons.
 Difference Between CDI in BF- 4 & 5
S.N BF-4
25. Injection Stop Conditions :
• Stop by operator.
• Blast Volume < 2200NM3/ Min
• Vessel Pr. - PIT 2188 < 1.0
• No. of healthy Lance < Set Min.
• Conveying N2 flow < 141 NM3/Hr.
• Receiving Tank Pressure < 9 bar
• Power Failure.
• Differential pressure/ Granular
flow alarms not Healthy.
• Inst. N2 Pr. Switch ( PSL2502) : Not
Healthy.
BF-5
Injection Stop Conditions
Normal Stop
• Stop by operator.
• CB Flow < 2200NM3/Min.
( FL- 6003)
• H.B.Pr.( PT5003) < 1.20 Bar.
• Blast Temp (TET6002)< 6000C.
• NIT 008 Tank Pressure < 10.5
bar.
• Diff. pressure/ Granular flow
alarms not Healthy.
• Inst. N2 Pr. ( PT0853) < 5.0 Bar
• Transport N2 Pr ( PT4411) < 2.5
bar.
Emergency Stop
• Transport N2 Pr ( PT4411)
>11.0 bar.
• Pr. Between Distributor &
• Bustle Main ( PT5001 – PT 5003 )
< (- )0.3 bar
• Transport N2 Flow ( FET4411)
< 400 NM3/Hr.
• PBV 4141 & or 4241 closes.
A> RAW COAL SYSTEM .

1. UNCONTROLLABLE SPILLAGE OF COAL

DURING MONSOON.

2. FREQUENT JAMMING OF CHUTES (FEEDER

BELT, S.I. CONVEYOR AND REVERSIBLE

CONVEYOR) DURING MONSOON.

A> RAW COAL SYSTEM

3. FIRE IN THE BAG FILTER OF DUST

EXTRACTION SYSTEM.

4. SNAPPING OF STEEP INCLINED

CONVEYORS

5. FIRE IN RAW COAL SILO

B> GRINDING SYSTEM

1. CONTROL OF CO PPM & O2% IN THE GAS.

2. FAILURES OF THE DIAPHRAGM PUMPS IN

THE “ON LINE GAS ANALYSER SYSTEM.

3. FAILURES IN THE D.C.C. (DRAG CHAIN

CONVEYOR)

4. HIGH VIBRATION IN CA FAN & ID FAN

LEADING TO INTERRUPITON IN
GRINDINGS.
B> GRINDING SYSTEM

5. LOCALISED SMOULDERING LEADING TO

BURNING OF BAGS IN THE MILL BAG
FILTER.
6. EXPLOSION IN MILL BAG FILTER.
7. CLOGGING OF THE COKE OVEN GAS
LINES IN THE PILOT BURNERS DUE TO TAR
& NAPTHA.
8. FREQUENT FLUCTUATIONS IN THE BF &
CO GAS PRESSURE.
C> INJECTION SYSTEM IN BF-4

1. OVERFILLING OF THE INJECTION VESSEL

DURING THE COMMISSIONING STAGE.

2. CONTINUATION OF INJECTION EVEN DURING

LOW BLAST / OFF BLAST CONDITION LEADING
TO JAMMING AND SPILLAGE OF COAL AT THE
TUYERE & TUYERE PLATFORMS.

3. FREQUENT JAMMINGS / PUNCTURING OF

COAL LINES.

4. FREQUENT TRIPPING OF INJECTION.

D> INJECTION SYSTEM IN BF-5
1. Failure of Safety Valve at 14.5 bar on 03.07.05 while
filling the tank (NIT 008) with Nitrogen. The valve was
suitably adjusted by GADI.
2. Lances could not be inserted in as received conditions
during the running conditions of the furnace on
04.0705 by DCR & GADI. The unit was to be
inaugurated on 5.07.05
3. Coal Valves at the distributor supplied by “ROTAX”
were not getting closed.
4. Difficulty in insertion of lance during running condition
of the furnace due to -
- Very heavy Lance
- Less clearance between the O.D of the lance & I.D of
the insertion sleeve.
- Gushing of hot air viciously
5. On 19.07.05 leakage developed in the junction of
lance/hose and hose/Ball valve of Coal Line, during
checking of coal valves by DC & GADI.

6. Puncturing of the Blow Pipe & filling of tuyeres with

slag in the furnace leading to loss of lances.

7. Emergency tripping of injection and burning of

rubber packing of all the lances & hoses. Teflon
packing in some of the lances valves also got burnt
on 08.08.05.

8. Stoppage of injection for 38 Hrs.

9. In complete/ Inadequate HMI.
- Reasons for tripping or other failures not being shown in
HMI.
- No alarm or event summary available.
- Information given in the training manual was too
inadequate to run the unit.
- 2 hrs presentation & a quick “Hands On” to start & stop
injection was given in the name of training.
- Fault diagnosis system is virtually absent in the HMI.
- Continuous defect in CDI totaliser system.
- Long absence of Process Experts form site immediately
after starting.

10. Frequent tripping due to pressure difference between the

distributor & bustle main below minimum. i.e. <(-) 0.300m
bar.
11. Proximity switches for 4112 got broken in Oct’05.
12. Less number of lance due to smaller port of nitrogen
purging valve PCV 0863, since commissioning.
13. Malfunctioning of PT 0853 in the instrument nitrogen
line.
14. Puncturing of Blow Pipe and filling of tuyeres with slag.
15. Frequent tripping of injection due to “MT 440 Pt. low”
from 17.12.05 - 20.12.05.
16. Power failure on 25.12.05 followed by TBS tripping of
TBS caused filling up of all working tuyeres.
17. Injection stooped but “hooter” did not function and the
Green display in the injection line for “Injection On” did
not go off a number of times.
18. All the injection start condition O.K. but
injectioncould not be started. As soon as the
injection is started, coal valves opens but
closes immediately.

19. Higher consumption of nitrogen than

contract.

20. Failure of bellows on the vibrator under the

feed tanks.

21. Problem in Server: - HMI screen Hangs,

Changing of screen becomes slow.
22. Failure of Pressure Transmitter in the
distributor & the furnace PT 5001 to PT
5004.

23. “Feed Tank” not coming in “In- Cycle”

24. Screen jamming.

25. Overfilling of Feed Tanks.

 3. Fluidization control
> FT fluidisation is controlled for the Actual volumetric flowrate, Am3/h.

Am3/
h

Am3/
h

10
Fluid
8
Rate
Am3/ 6
Hr 4
2
0
5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

CDI Rate ; Tons/Hr

 3. Fluidization control
• The coal must be continuously fluidized to ensure
smooth flow during injection.
• If fluidization is too low the coal flow from the FT will be
unstable.
• If the fluidization rate is too high injection rate control at
low injection rates will become unstable.

• Set point during pressurizing MAX 100% open

– To clean fluidization plate

• Set point during feeding 6 Am3/h

 4. Transport nitrogen control
H, M, L , VL

>Transport nitrogen flow rate is controlled in Nm3/h with FCV-4411.

tph Set point Nm3/h

oC

Nm3/h

bar

m3/h
 4. Transport nitrogen rate
• The transport nitrogen rate is around 950
Nm3/h at min. injection rate.
• In general higher rates lead to a more
stable injection behavior
– Thus during operation if unstable injection is
observed by the operators (violent fluctuations
in MT pressure PT-4411 and coal rate) a
higher transport gas rate should be used.
– Unstable injection may occur to factors such
as coals with a bad handleability and unstable
BF operation.
 5. Fluffing
> Fluffing is required to keep the coal fluidized in the ultra-high
dense line to the mixing-tee during feeding
> When FT is not feeding extra fluffing is used to ensure
smooth flow during feeding
> Fluffing must not be changed by operator during normal
operation
> If feed line blocks it can be blown clean by opening the
manual fluffing valves

* *PBV4161

PBV4171
When PBV4171 closes
PBV4161 opens
 6. FT batch cycle
Feeding > Injecting coal into the furnace

De-pressurizing > De-pressurizing empty FT from

injection pressure to atmospheric
pressure to allow filling
Filling > Filling of FT with coal from the FCS
via the sieves
Preparation

Slow-pressurizing > Slow-pressurizing with fluidizations

and fluffing nitrogen
Quick-pressurizing > Quick-pressurizing FT to injection
pressures of feeding tank with ORF
4112
Holding > Holding (waiting) period waiting
until feeding FT is empty to start
feeding, follows feeding FT
pressure set point
 6. FT batch cycle times
> Max. design CDI rate : 22 t/h
> Feeding / preparation time: 22 min
> Total cycle time (2FT) : 44 min

Feeding Slow-pressurizing
De-pressurizing Quick-pressurizing
Filling Holding

FT-410

FT-420

0 5 10 15 20 25 30 35 40 45

> No slow pressurization at maximum design rate due

to short feeding / preparation time
 6. FT batch cycle times
> CDI rate : 14 t/h Feeding Slow-pressurizing
> Feeding / preparation time: 34 min De-pressurizing Quick-pressurizing

> Total cycle time (2FT) :68 min Filling Holding

FT-410

FT-420

0 5 10 15 20 25 30 35 40 45 50 60 70 75

Quick-press. + holding = 12 min (constant for all CDI rates)

> Slow-pressurizing occurs between filling and quick pressurization if the cycle
time is long enough
> The total quick-pressurization time + holding time is then set to 12 minutes
> Slow-pressurization is used instead of a longer hold time to save nitrogen and
reduce wear of system valves
WIC4101
output %
7. Feed tank cycle graph WIC controlling t/h to t/h SP

Holding
PdIC4101 DP SP from FT420 Holding
DP SP
DP
Depress. QuickQuick press.
pressurization

Slow press.

Slow
Filling pressurization

t/h SP
t/h
FT420 feeding

Start Preparation FT410

Start feeding
Start feeding FT410
8. Purging / Cooling injection lines
• Purging - cleaning
– Cleaning of build-up in lines and on lance tip
(ash)
– High velocity per line

• Cooling – emergency / cooling

– Purging of all lines simultaneously for cooling
only (not cleaning)
– Lower velocity than for cleaning
– Lances without PCI injection must always be
cooled during BF operation to protect the
injection lances
 8. Purging injection lines - system
x 20
Coal flow switch

x 20

PIT 5002

CHV5002 CHV5005
PIT 5004

BAV5002 SDV-5005

DP blowpipe

PCV-0863 (FO)

PURGE NITROGEN

* Not presently available

GLV-0861

*EMERGENGY PURGE AIR

9. Purging injection lines
• Automatic cycle
– Selected by pressing “Start” on Distributor screen
– 2 minutes per lance all lances from 1 to 20
– Interval between cycles chosen by operator (2.5 to
8 hour), nominal time = 8 hours
• Manual
– Operator selects lance and duration on lance pop
up on Distributor screen
• Automatic safety interlocks
– Flow switch shows no coal flow (>5 sec)
– Pressure drop across blow pipe drops below
operator set limit (>5 sec)
– The automatic safety interlocks can be disabled
on the lance pop-up menu on the Distributor D-
500 screen