Presentation on BHEL Steam Generators

BHEL Steam Generators

by
Veerendar Aluvala
DM/BHEL/Tiruchy

Bharat Heavy Electricals Limited - Tiruchy

Presentation on BHEL Steam Generators

Presentation Summary
Pulverised Coal Combustion (PCC)

Design Aspects

Boiler Parameters

Drum Type Boilers

OTSC Boilers

Fuel Analysis

Site Conditions

Firing System

Auxiliaries Selection

Pollution Reduction

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Technology Developments

Pulverised Coal Combustion (PCC)

Fluidised Bed Combustion (FBC)

Circulating Fluidised Bed Combustion (CFBC)

Combined Cycle Gas Turbine/Co-generation Plants

Integrated Gasification Combined Cycle (IGCC)

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Pulverised Coal Combustion (PCC)

PCC is the most commonly used method in coal-
fired power plants and is based on many decades
of experience.

The technology is well developed and understood

and there are thousands of units around the world.

Boiler design - two broadly different arrangements

are used for PCC boilers - conventional two-pass
or single-pass tower type.

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Pulverised Coal ?
Fineness of pulverised coal not being less than
70% thru 200 mesh (75 microns) and 98% thru 50
mesh (300 microns).

Pulveriser is required

Gas velocities 10-12 m/s

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Tower Type Basic Boiler Configurations

Conventional Two Pass

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Typical
500MW

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Design Aspects
Basic Data For Design
Boiler Paramters
Fuel Data
Site Data

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Boiler Parameters

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Rankine cycle

 The Carnot Cycle is theoretically most efficient, but it is having practical

difficulties.
 For steam power plant, practical thermal cycle was suggested by Rankine,
called Ideal cycle or Rankine cycle.

T
T1 4 1 3-3’ – BFP raises pressure from p2 to p1
p1
3’-4 – Heating In feed heaters & economizer
3’ 4 -1 – Heating In boiler
1-2 – Work done in Turbine from p1 to p2
T2 2 2-3 – Heat reduction in condenser
3 p2

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Rankine cycle with Superheater

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Methods of increasing Rankine Cycle Efficiency

 Raising supply temperature by super heating.

Increasing the inlet temperature will raise the heat
supply to the cycle more than the heat rejection.

 Raising inlet pressure of steam :

Increasing the pressure will mean increase in saturation
temperature at which steam evaporates thus increasing
the average temperature (T1) of heat addition.

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Methods of increasing Rankine Cycle Efficiency

(Contd..)

 Dropping the final pressure (or temperature) at which heat is rejected.

 Regenerative Heating : Heating the feed water pumped to Boiler by bleeding

steam from turbine.

 Reheat Cycle : Reheating of steam in boiler after it has already expanded in

HP Turbine will avoid moisture formation in LP Turbine. Also, more heat
content of steam before IP Turbine, will improve efficiency.

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Heat Balance Diagram (Typ.)

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Boiler Parameters define

heat duty of the boiler

Heat fired = (SH + RH) heat duty

÷ Boiler Efficiency

Coal fired = Heat fired / HHV of coal

Air quantity = kg. of air/kg. of fuel x Qty. of

coal fired

Gas quantity = Coal + Air – Ash in coal

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Heat Absorption by various types of Boilers

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Increase of Plant Cycle Efficiency due to

Steam Parameters

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UTILITY BOILER TECHNOLOGY GROWTH

30 SUB CRITICAL SUPERCRITICAL
800 MW & above
CONTROLLED CIRCULATION ONCE THROUGH
HEAT RATE IMPROVEMENT %
NATURAL
300 ata,
CIRCULATION 25 700°C/700°C
25 660 / 800MW
250 ata,
568°C/598°C
500 MW 20.5
210/250 MW 500 MW 170 ata,
20
150 ata, 170 ata, 540°C/568°C
540°C/540°C 540°C/540°C 17.
110/200 MW 2
15.7
130 ata, 14.6
15 540°C/540°C
12.5
60/100 MW
96 ata,
10 540°C

0
1960 1970 1980 1990 2000 2010 2020

YEAR
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Implications of Steam Parameters on

Boiler Design

Boiler type

Materials

Reliability and Availability

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Types of boilers
Drum type

Once-through type

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Drum type boiler

Steam generation takes place in furnace
water walls
Fixed evaporation end point - the drum
Steam -water separation takes place in
the drum
Separated water mixed with incoming
feed water

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Drum Type Boiler

Natural Circulation Boiler

Circulation thru water walls by

thermo-siphon effect

Controlled Circulation Boiler

Thermo-siphon effect supplemented

by pumps

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Boiler Water Circulating Systems

Choice of Circulating system depends on

Operating Pressure

The density difference between water and steam

provides the driving force for the Circulating fluid

Higher pressures units warrant pumps to ensure

circulation (Natural circulation not adequate)

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Drum Internals

NATURAL CIRCULATION
CONTROLLED
CIRCULATION

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Types of Circulation

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Types of Circulation

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Supercritical:
Pressure > Supercritical
(221 bar)

Ultra Supercritical:

Supercritical with SHO

temperature > 593 deg.C

Adavnced Ultra
Supercritical:

Supercritical with SHO

temperature > 700 deg.C

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Once Through Boiler

• Once -through flow through all sections of
boiler (economiser, water walls &
superheater)

• Feed pump provides the driving head

• Suitable for sub critical & super critical

pressures

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Operating Pressure Range

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Once-thru Boiler
Major differences from Drum
type boiler :

• Evaporator system
• Low load circulation system
• Separator

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Once -thru Boiler

Evaporator system :

• Formed by a number of parallel tubes

• Tubes spirally wound around the furnace to reduce

number of tubes and to increase the mass flow rate thru’
the tubes

• Small tube diameter

• Arrangement ensures high mass velocity thru the tubes

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Once -thru Boiler-Furnace Wall

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Spiral Tube Arrangement

Features

 Reduced number of
tubes with pitch.

 Increased mass flow.

 Mass flow rate can

be selected by
number of tubes.

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Spiral Water wall Tubing

Lateral Heat Flux Profile

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Spiral Furnace
Windbox Panel

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Sliding Pressure Supercritical Design

Spiral to Vertical Transition Area - Load Transfer

Support
Fingers

SPIRAL WALL SUPPORT

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Vertical Furnace Wall Design

Vertical tube furnace walls will

provide all the operational benefits
of the currently popular spiral design
while significantly reducing the cost
and construction time for the furnace
and providing some reduction in
pressure drop.
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Vertical Wall
Windbox

Only a Few
Bends at the
Top and Bottom
Straight
Tubes

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SUB CRITICAL Vs SUPER CRTICAL

Particulars Sub critical Super critical

Type Drum type Once through Once through

Operating pressure Below 221.1 bar Below 221.1 bar Above 221.1 bar

Boiling (Two No boiling process.

Steam generation Boiling (Two phase
phase heat Phase change is
process heat transfer)
transfer) gradual.
Thick walled Thick walled drum is
Smaller vertical separators provided
component provided
Start up and load
Base Better start up and load change rates
change rates
Water wall Generally spiral wall.
Vertical
construction Vertical wall for higher capacity
Higher loads: Once through
Circulation Circulation at all loads
Lower loads : Circulation

Water quality Base More stringent requirements

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Comparison of Parameters
PARAMETER UNIT 500 MW 800 MW
Main Steam Pressure ATA 170 247
Main Steam Temp O 537 565
C
Main Steam Flow T/Hr 1,515 2,340
Reheat Pressure ATA 41 56.6
Reheat Temperature O 537 593
C
Reheat Flow T/Hr 1,335 1,940
Cold Reheat Pressure ATA 45 61.5
Cold Reheat Temp O 336 348
C
Final FW Temp O 253 290
C
BMCR T/Hr 1,625 2,600

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Coal Analysis

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Effect of coal rank on sizing of a pulverized-fuel
furnace (constant heat output)

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Comparison of Furnaces for Different Fuels

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Effect of Fuel on Boiler Design

Specifying wide range of coal properties have the
following implications:

If pulverising/firing equipment is oversized, turn

down is limited and auxiliary power consumption
will go up.

If furnace is oversized, attaining rated SH, RH outlet

temperature becomes difficult.

If pulverisers and airheaters are oversized to handle

occasionally high moisture coals, there will be
excessive tempering air and higher gas outlet
temperature when handling normal moisture coals.

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Coal - Challenges

Coals vary widely in their properties

- mine to mine and seam to seam

Coal firing therefore presents a varying

set of demands before the boiler
designer

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Normally specified Coal Properties

Proximate Analysis
Ultimate Analysis
Calorific Value
Ash Constituents
Ash Fusion Temperatures
Hard Grove Index
YGP Index

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Coal Analysis -Typical Indian Coals

Proximate Analysis

Unit Design Worst Best

Coal Coal Coal
Fixed carbon % 22.0 20.0 25.0
Volatile matter % 21.0 19.5 23.0
Moisture % 15.0 16.5 14.0
Ash % 42.0 44.0 38.0
Total % 100.0 100.0 100.0
HHV Kcal/kg 3300 3000 3600

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Coal Analysis -Typical Indian Coals

Ultimate Analysis
Unit Design Coal Worst Coal Best Coal

Carbon % 33.73 30.90 38.26

Hydrogen % 2.35 2.09 2.49
Oxygen(difference) % 5.48 5.00 5.96
sulphur % 0.37 0.36 0.38
Nitrogen % 0.75 0.85 0.57
Moisture % 15.00 16.50 14.00
Ash % 42.00 44.00 38.00
HARD GROVE INDEX 55 54 56

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Ash Characteristics -Typical Indian Coals

Design Worst Best

Initial Deformation Temp. Deg.C 1150 1100 1200

Hemispherical Temp. Deg.C 1400 1400 1400
Fusion Temp. Deg.C 1400 1400 1400
Ash Analysis:
A – SiO2 % 60.08 61.40 60.30
A – Al2O3 % 29.50 28.50 29.80
B – Fe2O3 % 4.10 3.90 4.70
B – CaO % 1.70 1.93 1.57
B – MgO % 0.75 0.92 0.59
B – Na2O + K2O % 0.65 0.85 0.53
A – TiO2 % 1.70 1.60 1.80
- P2O5 % 0.80 1.10 0.13
- SO3 % 0.27 0.31 0.25

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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

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Ash Analysis
Provides indicators to
Slagging / fouling / deposition potential
Erosion potential
Corrosion potential

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Boiler design

Coal Properties influence

The sizing of the boiler heat transfer surfaces

The flue gas velocities

The size of boiler auxiliaries

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Boiler Efficiency

ThIs is influenced by coal properties,

ambient temp. & relative humidity,Boiler
exit gas temp.
Determines the heat input to the boiler
Forms the basis for air & gas weight
calculations, quantity of coal fired

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Furnace design
Furnace for Burning Pulverised Coal are Designed
To prevent formation of slag deposits
To allow complete combustion by providing adequate
retention time.
Temperature at entry to closely spaced SH/ RH sections is
brought down well below the lowest of the ash softening
temperatures.
Adequate mass flow through water wall tubes so that tube
metal temperatures are well within allowable limits.
Ensuring the above in design stage will lead to high boiler
availability

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Furnace Design ( contd…..)

The furnaces of BHEL boilers are conservatively sized with low
heat release rates to ensure maximum output all the times.

 The possibility of slagging and fouling of heat transfer

surfaces is minimised even while firing worst type of fuels.

 Furnace design accommodates wider range of coals

normally experienced by Indian utilities.

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Furnace Selection Criteria

Cross Sectional Area Heat Release Rate - NHI / PA
Effective Projected Radiating Surface Loading - NHI/ EPRS
Volumetric Heat Release Rate - Q Fired / Volume
Burner Zone Heat Release Rate – Q Fired / FZS
Furnace Residence Time
Distance Between Furnace Bottom-hopper & Lower Most Fuel Nozzle
Distance Between Upper Most Fuel - Nozzle & Bottom of SH
Furnace Exit Gas Temperature (FEGT)
Furnace Bottom Opening

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Comparison of BHEL Furnace

With International Competitor - 500 MW

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Furnace Comparison - 500 MW

BHEL International
competitor

Furnace plan area m2 303 276 ( - 10 % )

Furnace volume m3 16229 13125 ( - 24 % )

EPRS m2 7608 6690 ( - 14 % )

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SH / RH / ECONOMISER
Design criteria
Adequate heating surface to get rated SHO / RHO
temperature over control load for the range of
coals.
Low gas velocity to minimise pressure part
erosion
Proper tube spacing to prevent plugging and
fouling of heat transfer surfaces
Proper pressure part support and alignments

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Air & Gas Systems

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Bisector Primary and Secondary System

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HOT SECONDARY AIR DUCTING

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COLD PRIMARY AIR DUCTING

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Hot Primary Air Bus to Mill &

Tempering Air Duct

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Firing System

Wall firing

Tangential firing

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Combustion in Tangential Corner Firing Furnace

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Tilting Tangential Corner Firing Furnace

Selective furnace utilization and steam
temperature control are accomplished
by tilting nozzles in a tangentially fired
system

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Windbox Assembly

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Windbox Arrangement (Typical)

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Coal Combustion

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Boiler auxiliaries
Design Criteria
Airheaters shall be sized for optimum gas temperature
while firing design coal for better boiler efficiency and
sufficient hot air temperature shall be available for mill
drying while firing high moisture coal.

Sufficient margins shall be provided on volume and

head while selecting FD/ID/PA fans so that no
capacity limitation will be experienced.

ESP to be sized to meet pollution norms with higher

SCA.

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Airheaters

Recuperative (Tubular airheater)

Regenerative (Ljungstrom / Rothamuhle)

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Airheater Selection
Gas temperature entering airheater

Gas quantity entering airheater

Air quantity leaving airheater

Desired pressure drop on air/gas side

Gas temperature leaving airheater

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Regenerative Trisector Airheater

4
3

1.PRIMARY AIR IN
5 2.SECONDARY AIR IN
3.PRIMARY AIR OUT
4.SECONDARY AIR OUT
5.GAS IN
6.GAS OUT

1
6 2 404

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Milling And Firing System

Design Criteria
Choice of mill - vertical spindle or tube mill
depending on coal characteristics / customer
choice.
Capacity to meet the range of coals specified.
Pulveriser selection shall ensure one spare mill.
Fuel pipes shall be sized to minimise erosion and PF
settlement.

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Mill Selection

Quantity of coal fired

% moisture

PF fineness required

Hard Grove Index

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MILLING PRINCIPLE
1. Hammering
2. Attrition
3. Crushing

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Mills

Low speed (Tube)

Medium speed ( Vertical Spindle – Bowl /
Balls & Race / MPS / E)
High speed (Beater Wheel)

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Bowl Mill (General Arrangement)

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Air and Coal Circuit of Tube Mill

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Beater Mill

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Fan Selection
Volume
Head to be developed
Temperature
Density

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TYPES OF FANS
• Axial flow fan-main flow is parallel to the axis of
rotation of the fan
a)Impulse type: most of the energy coming out of the
impeller is kinetic energy.
b)Reaction type: most of the energy coming out of the
impeller is pressure energy.
• Radial(centrifugal) flow fan-flow is perpendicular to the
rotational axis of the impeller. There are three type of blade
configuration.
a)Backward curve.
b)Forward curve.
c)Radial bladed.
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Axial Reaction Fan (Single Stage)

AIR SUCTION CHAMBER IMPELLER

OUTLET BLADE

SHAFT

SERVO MECHANISM DIFFUSER

(FOR BLADE PITCH CONTROL)

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Radial Fan (Double Suction)

DAMPER ASSY.

SUCTION CHAMBER

IMPELLER

SHAFT SPIRAL CASING

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Performance Curve For Axial Reaction Fan

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Performance Curve For Radial Fan

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Performance Curve For Radial Fan with VFD

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Dust Collection System

Mechanical Precipitator

Electrostatic Precipitator

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ESP Selection
Gas volume to be handled

Gas temperature

Inlet dust concentration in gm/Nm3

Outlet dust concentration in mg/Nm3

% moisture in flue gas

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ESP

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Factors affecting the ESP performance

(A) Characteristics of dust:
Particle size distribution
Dust loading
Chemical composition
Electrical resistivity
Adhesive/cohesive properties
(B) Characteristics of gases :
Temperature
Chemical composition
Moisture content
Quantity to be handled

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Atmospheric Pollution Reduction

To control the emission of pollutants (co2, sox, Nox,
particulates), BHEL has implemented the following new
developments:
Over-fire air in the windbox, low nox concentric firing
system that reduce nox level by nearly 40% in
conventional coal-fired boilers.
Low excess air oil burners (nox reduction)
AFBC/CFBC boilers (Nox and Sox reduction, sulphur
capture in bed).
Electrostatic precipitators to reduce particulate emission
as low as 40 mg/Nm3.
Bag house filters are being introduced to reduce
particulate emission level to less than 25 mg/Nm3 and
essentially for capture of p10 (< 10u) particles.

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NOx

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Low NOx Concentric Firing system

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Low NOx Concentric Firing system

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Challenges in Boiler Design

Fuel Flexibility

High Ash Indian Coals

Blending of coals

Materials for high temperature applications

Fabrication techniques for new materials

Pollution Control

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