PERCAPITA ELECTRIC POWER CONSUMPTION

COUNTRY PERCAPITA ELECTRICPOWER CONSUMPTION KWH KWH 367 773 16413 13040 1439 7346 7069 5968 4072 5108 4610 15244 6406 1259 7749

INDIA CHINA CANADA USA MEXICO NORWAY 24033 SWITZERLAND FRANCE UNITED KINGDOM SPAIN RUSSIA ITALY SWEDEN GERMANY TURKEY JAPAN

These are collected from Ststistics Organisation for Economic Cooperation and Development of I.E.A.

GROWTH OF UNIT SIZES IN INDIA

RATING 30/70 MW 110/120 MW 200/210 MW 250 MW 500 MW 660 MW YEAR OF INTRODUCTION 1965 1966 1972 1991 1979 Proposal Stage

BHEL UTILITY BOILERS

Size No. of Boilers 4 35 45 29 20 103 11 28 30MW 60/67.5/70/80 MW 100MW/110MW 120MW/130MW 200MW 210MW 250MW 500MW

TOTAL

275

BHEL CONTRIBUTION TO POWER SECTOR

BHEL-BUILT SETS ACCOUNT FOR NEARLY 65% OF THE INDIAS TOTAL INSTALLED CAPACITY OF OVER 1,01,000 MW

Steam St Generators G t -contracted t t d

Power Boilers: 30 to 130 MW 200/210/250 MW 500 MW CFBC HRSG Process Plant Boilers: Chemical Recovery Conventional Firing CFBC AFBC HRSG 113 130 28 2 L Largest t 125 MW 48 For GTs Fr 3, 5,6 & 9 and V 94.2 16 129 1 52 55 Largest 675 TPD Largest 320 t/hr. t/hr Largest 175 t/hr. Largest 165 t/hr Largest 127 t/hr

Total 574

AS THE UNIT SIZES GREW, GREW BOILER SIZES SUPPLYING STEAM TO SUCH TURBINES HAVE ALSO INCREASED
SIZE FLOW (T/H) 150 260 375 690 805 1670 PRESSURE (KG/CM2) 63 96 139 137/156 156 179 TEMPERATURE (DEG C) (DEG.C) 490 540 540/540 540/540 540/540 540/540

30MW 60/70MW 110/120MW 200/210MW 250MW 500MW

BASIC DATA FOR DESIGN

BOILER PARAMTERS FUEL DATA SITE DATA

HEAT BALANCE DIAGRAM

190.0 505.344 814.7 535.0

HPT

LPT

LPT

BOILER

31.07

736.2

27.89

844.8

459.544 335.7

459.544 535.0 0.0890 360.130 580.9 (0.9384)

C 241.7 234.0

505.944

D HPH HPH LPH LPH LPH LPH CP

FP

FUELS HANDLED
COAL/OIL/GAS IN ANY COMBINATION LIGNITE BLAST FURNACE GAS/COKE OVEN GAS CARBON MONOXIDE COAL TAR BLACK LIQUOR BAGASSE RICE HUSK WASHERY REJECTS WHEAT/ / RICE C STRAW S

FUEL ANALYSIS COAL

COAL PROPERTIES AFFECTING BOILER DESIGN

TYPE OF COAL ( ANTHRACITE, BITUMINOUS, LIGNITE) HIGHER HEATING VALUE VOLATILE MATTER MOISTURE CONTENT ASH CONTENT ASH CHARACTERISTICS HARD GROVE INDEX ( HGI )

INDIAN COALS Vs COALS OF OTHER COUNTRIES

INDIA GERMA NY RUHR 8.5 20.5 8.0 1.5 6700 12 USA CANA DA ALBE RTA 4.0 18.0 8.5 0.5 7600 11 AUSTRLIA

Coal MOISTURE VOL. MATTER ASH SULPHUR HHV COAL ASH % % % % KCAL/KG PER MKAL KG

A 15.0 20.0 40.0 0.5 3200 125

B 12.0 18.0 40.0 0.3 3500 114

C 12.0 30.0 30.0 0.2 4500 67

WESTERN 16.0 33.0 8.0 0.5 5730 14

NSW 8.0 29.0 15.7 0.69 6200 25

CHARACTERISTICS OF TYPICAL INDIAN COAL

HIGH ASH HIGHLY ABRASIVE MEDIUM MOISTURE MEDIUM VOLATILE MATTER LOW HEATING VALUE (HHV kcal / kg) LOW SULPHUR (35 50%) (55 65%) (10 15%) (18 24%) (3000 3500) (0.2 0.5%)

PROBLEMS ASSOCIATED WITH INDIAN COALS

INCONSISTENT COAL PROPERTIES PRESENCE OF EXTRANEOUS MATTERS IN COAL HIGH QUANTUM OF ASH WITH HIGH PERCENTAGE OF QUARTZ HIGHLY ABBRASIVE NATURE OF COAL ASH DUE TO LOW SULPHUR CONTENT- EXTREMLY HIGH ELECTRICAL RESISTIVITY OF ASH LOW HEATING VALUE OF THE COAL

FURNACE SELECTION CRITERIA

NHI / PA NHI / EPRS Q FIRED / VOLUME BURNER ZONE HEAT RELEASE RATE FURNACE C RESIDENCE S C TIME DISTANCE BETWEEN FURNACE BOTTOM-HOPPER & LOWER MOST FUEL NOZZLE DISTANCE BETWEEN UPPER MOST FUEL - NOZZLE & FURNACE OUTLET TEMPERATURE ASPECT RATIO BOTTOM OF SH

FURNACE HEAT LOADINGS

EPRS LOADING PLAN AREA LOADING VOLUMETRIC LOADING BURNER ZONE HEAT RELEASE RATE

PLAN AREA LOADINGS FOR BHEL BOILERS

DESCRIPTION NET HEAT INPUT FURNACE PLAN AREA FRING ZONE SURFACE NHI / PA NHI / FZS

UNIT 6 10 Kcal/h m m 2 2

67 5 MW 67.5 189 62.4 86.8 3.03 2.18

120 MW 319 78 126.9 4.09 2.51

210 MW 542 147 254.4 3.69 2.13

500 MW 1270 276 621.8 4.61 2.04

6 2 10 Kcal/ m h 6 2 10 Kcal/ m h

VU40 RENUSAGAR 67.5MW

CESE CALCUTTA 67.5 MW

110 MW SABARMATHI

120 MW BOILER NALCO

Prai Thermal Power Station 3 x 120 MW

Pasirgudang TPS 2 x 120 MW

Tripoli (W) TPS 2 x 120 MW

200 MW NTPC KORBA

210 MW TNEB - TUTICORIN

210 MW APSEB VIJAYAWADA - 1

210 MW NTPC NCTP-DADRI

210 MW APSEB VIJAYAWADA-3 TOWER TYPE

210MW TOWER TYPE NEYVELI

CONTROLLED CIRCULATION STEAM GENERATORS

500MW TROMBAY-5 BOILER

500 MW NTPC SINGRAULI 6

ONCE THROUGH STEAM GENERATORS

Once -thru Boiler-Furnace Wall

500 MW TALCHER NTPC NTPC (Sub critical oncethrough)

INDUSTRIAL STEAM GENERATORS

BHEL Industrial Boilers

1 2 3 4 5 6 7 VP VU 60 VU 40 VU 40S VU 60S MU V2R Vertical Package Boiler Vertical Unit Vertical Unit Vertical Unit (Stoker) Vertical Unit (Stoker) Modular Unit Chemical Recovery y

Industrial Boilers - Capacity

Type C Capacity t/h VP VU 60 VU 40 VU 40 S VU 60 S MU V2R Max.Design Pressure k / 2(g) kg/cm ( ) 0C 125 125 125 125 125 125 125 Temperature

10-250 10 250 60-450 100-480 100 480 50-125 30-70 80-350 140-675(TPD)

515 540 540 500 485 540 480

VP Boiler Design Features

Bi-Drum Bottom supported Natural Circulation Wall firing - Oil/Gas Pressurised/Balanced Draft Welded Furnace Wall Single/Multi Pass Gas Flow across Boiler bank Drainable Superheaters Economiser and/or Airpreheater. Minimum Refractory & Insulation Wide steam temperature control range Fast response to load swings

VU60 Boiler Design Features

Bi-Drum Bottom supported Natural Circulation Front wall/Tangential Firing - Oil/Gas Pressurised / Balanced Draft Welded Furnace Wall Multi-Pass Multi Pass Gas flow across Boiler Bank Economiser and/or Airpreheater Minimum Refractory y & Insulation Wide steam temperature control range Fast response to load swings g

VU40 Boiler Design Features

Bi-Drum Top supported Natural Circulation Tangential/Front wall Firing -Coal/Oil/Gas Balanced Draft Welded Furnace wall Single Pass Gas flow across Boiler Bank Economiser and Airpreheater Minimum Refractory & Insulation Fast response to load swings

VU40 (Stoker) Boiler Design Features

Bi-Drum Top supported Natural Circulation Grate Firing - Coal/Lignite/Cellulose Fuels Balanced Draft Welded Furnace wall Single Pass Gas flow across Boiler Bank Economiser and Airpreheater Minimum Refractory & Insulation Fast response to load swings

MU Boiler Design g Features

Single Drum Natural Circulation Bottom or top supported Fully welded construction D i bl S Drainable Superheater h t Integral Economiser Pressurised/Balanced Draft Wider control range Minimum Refractory & Insulation Quick start-up Less space requirement

V2R Recovery Boiler Design Features

Bi-Drum top supported Natural Circulation Balanced Draft Welded Furnace Wall Widely spaced Tangent tube SH Single Pass Gas Flow across Boiler bank Vertical straight Finned Economiser Twin wheel cascade evaporator system or Large Economiser system. Suspension firing system with multiple black liquor guns Decanting hearth O ti i d combustion Optimised b ti air i system t HEA ignitors for starting burners Minim m Refractor Minimum Refractory & Ins Insulation lation Additional QC checks for WW tubes

IMPLICATIONS OF HIGHER STAEM PAREMTERS ON BOILER DESIGN

BOILER TYPE MATERIALS RELIABILITY AND AVAILABILITY

NEED FOR PROPER MATERIAL SELECTION

PROPER SELECTION ENSURE SAFE - METAL TEMPERATURE UNDER ALL - OPERATING CONDITIONS PROPER SELECTION HELPS IN - - ---REDUCING THE INSTALLATION COST.

SELECTION OF AUXILIARIES
AIRHEATERS FANS MILLS ELECTROSTATIC PRECIPITATOR

AIRHEATER PERFORMANCE VARIATIONS

Fuel moisture Airheater leakage Airheater seals Gas temperature leaving p g the airheater

MILL PERFORMANCE VARIATIONS

MILL OUTLET / INLET

TEMPERTURE HGI / HHV

FUEL QUALITY LIKE MOISTURE /

FAN PERFORMANCE
LOADING OF FANS POWER CONSUMPTION

ESP PERFORMANCE VARIATIONS

DUE TO AIR HEATER LEAKAGE DUE TO HIGHER GAS TEMPERATURE LEAVING AIR HEATERS

MAJOR VARIABLES AFFECTING THE BOILER PERFORMANCE EFFECT OF BOILER PARAMETERS FUEL ANALYSIS VARIATIONS VARIATIONS IN AUXILIARY EQUIPMENT PERFORMANCE VIZ ., MILLS, AH,FANS

OPERATING VARIABLES AFFECTING SLAGGING

EXCESS AIR DISTRIBUTION OF AIR DISTRIBUTION OF COAL FINENESS OF COAL NUMBER OF OPERATING BURNER ELEVATIONS FREQUENCY Q OF WALL BLOWER OPERATION LOADING OF BLOWER

OPERATING CONDITIONS AFFECTING THE PERFORMANCE

LOW PRESSURE OPERATION HIGHER EXCESS AIR HP HEATER NOT IN SERVICE GRID FLUCTUATIONS

FUEL QUALITY AFFECTING THE PERFORMANCE

SLAGGING FOT VARIATION SH / RH SPRAY VARIATION FLUE GAS TEMPERATURE LEAVING BOILER MILL LOADING AUX .POWER CONSUMPTION BOILER EFFICIENCY

USE OF INDIAN COALS DESIGN CONSIDERATIONS

BOILERS: O S CONSERVATIVE FURNACE HEAT LOADINGS LOWER FLUE GAS VELOCITY OVER TUBE BANKS PLAIN TUBE IN LINE ARRANGEMENT OF HEAT TRANSFER SURFACE -OPTIMUM END GAPS TO AVOID PREFERENTIAL GAS FLOW -EROSION SHIELSA / CASSETTE BAFFLES -EROSION ALLOWANCE FOR LEADING TUBES -CAST STEEL PF BENDS & CERAMIC LINEDPF BENDS *BOILER AUXILIARIES -IMPROVED IMPROVED SEALING ARRANGEMENT -EXTENDED TUBE-TUBULAR APH -LOW SPEED RADIAL ID FANS -LINED IMPELLERS OF RADIAL FANS IN AIRHEATERS

STEAM & WATER CIRCUIT

DRUM S1 S2 S3 S4 S5 S17 S6 S7 S9 S18 S11 S8 S11 S19 S9 S5 S6 S7 S18 R1 S17 R2 R3 R4

S20 S14 S15

S12 S13 S14 S15 S10 S16 S21 S22 S23 S24 S25

S20

DESH

RH SYSTEM

LOW TEM P SH E7 E6 E5 E4 PLATEN SH S29 E3 S30 S31 E2 E1 F IN A L S H S33 E3 E5 E4 E7

S26 S27 S28

S32

SH SYSTEM

ECO SYSTEM

SCHEME OF AIR & GAS DUCTS / CIRCUITS

COLD PA SYSTEM

FURNACE SLAGGING INDICES 1 BASE / ACID RATIO 1.

Fe2 O3 + Cao + Mgo + Na2O + K2O SiO2 + Al2O3 + Tio2
Slagging potential: B/A
(B)

(A) ( )

<

0.25 Low

0.25 - 0.40 Medium 0 40 - 0.70 0.40 0 70 Hi High h

(Eastern and Midwestern Bituminous Coals) ( )

2.SULPHUR INDEX
B A x S (% By weight in Fuel Dry Basis)

< 0.6 2.0 >

0.6 2.0 2.6 2.6

Low Medium High Servere

Bituminous if

Fe2 O3 > Cao + Mgo

3. IRON / CALCIUM RATIO

Fe2 O3 / CaO
(OR)

Fe2 O3 / CaO + MgO (if MgO % is more)

0.3 3.0 High Slagging

4.FUSION INDEX
HT + 4 IT Rs = 5

HT=Hemi spherical temperature IT =Initial Fusion Temperature

Rs:1230- 1340 Medium 1150- 1230 High <1150 Severe

5.VISCOSITY / ASH FUSION TEMPERATURE {T250 Poise (Oxid)T10,000Poise(Red)} Rs= 97.5 x fs

Mid Point Temp. at 2000 Poise 2000 Deg. F 2200 2400 2600 Rs < 0.5 1.0 > 0.5 1.0 2.0 2.0 fs Value 1.2 2.0 32 3.2 5.2 Low Medium High Servere

6.SILICA / ALUMINA RATIO

SiO2 Al2 O3

<
1.7

1 7 Low 1.7 - 2.8 Medium - 2.8 High

>

7.DOLOMITE PERCENTAGE
CaO + MgO DP= x100

Fe2 O3 + CaO + MgO + Na2O + K2O

Coal with Basic Oxide > 40 % Lower the DP Higher the Slagging Potential.

8.SODIUM OXIDE
Na2 O % By Weight of Ash

<
1.0

1.0 Low - 2.5 Medium - 2.5 High

>
Western Coals and Lignites

9.SODIUM AND POTASSIUM OXIDE

Na2 O + K2 O % By Weight of Ash

<
3.5

3.5 Low - 5.0 Medium - 5.0 High

>
Western Coals and Lignites

10. IRON OXIDE

Fe2 O3 % By Weight of Ash

<
12

12 Low - 25 Medium - 25 High

>
Western Coals and Lignites

TOWER TYPE BOILERS ADVANTAGES

A TRULY SINGLE PASS ELIMINATES CHANGE IN DIRECTION OF GAS FLOW MINIMISES EROSION OF PRESSURE PARTS. INHERENTLY LOW GAS VELOCITY DUE TO SH / RH SPACING LESSER EROSION OF PRESSURE PARTS. PARTS DRAINABLE SH ,RH SECTIONS START UP AND SHUT-DOWNS. SHUT DOWNS FASTER START-UP OCCUPIES LESS GROND SPACE. ADOPTED THROUGHOUT EUROPE WELL ESTABLISHED DESIGN

TWO PASS Vs TOWER TYPE

G flow Gas fl passes No. of turns Gas velocity Erosion Potential Height g of Boiler Weight of boiler Erection`

2 2 Base Base Base Base Multi f front t

1 None Lower Less + 30 % + 5 % - 15 % Single front