PLANT EFFICIENCY & HEAT RATE
482.8 Mkcal/hr 420 Mkcal/hr 180.6 Mkcal/hr 172 Mkcal/hr
boiler 210
T
MW 200 MW
120.7 t/h auxpower 10 MW
4000 kcal/kg
87.0 % 2000 kcal/kwhr 43.0 %
2299 kcal/kwhr 37.4%
2414 kcal/kwhr 35.6 %
Heat Balance for Steam Process
Energy Input
Feed Water Steam @ Pressure
P1
Usefull
Energy Input Steam Process Energy
Air & Fuel Output
P1
Energy Energy Energy
Loss Loss Loss
Flue Blow Down Due to Piping
Gas Water Friction Loss
Equipment etc.
Energy Output = Energy Input - Losses
BOILER EFFICIENCY TEST
METHODS:
Direct Method
In-direct Method
Codes Being followed:
ASME PTC 4 – 1998
BS 2885 (revised as BS EN 12952-15:2003)
IS 8753 / 1977
DIN 1942
ISO R 889 / 1968
DIRECT METHOD
Efficiency = Output / Input
= Heat absorbed by working fluid * 100
(Heat in Fuel + Heat Credits)
Heat Credits
Heat in entering air
Heat in Atomizing steam
Sensible heat in fuel
Pulverizer power
Boiler Circulating water pump power
Heat supplied by moisture in entering air.
DIRECT METHOD
ADVANTAGES DISADVANTAGES
1. Based on the definition 1. Flows (Feed water & Fuel) of
Efficiency. Should be measured very
accurately.
2. Very less no of readings 2. Less accuracy
3. Capacity and output data 3. Identifying and correction
also can be checked to the losses area is not
possible.
4. Does not provide for
corrections of test results
to Standards or Guarentee
conditions.
INDIRECT METHOD (HEAT LOSS METHOD)
Efficiency = 100 – (Heat Losses * 100)
(Heat in Fuel + Heat Credits)
Heat Losses
Unburnt carbon loss
Dry gas loss
Fuel hydrogen loss
Fuel moisture loss
Air moisture loss
Carbon mono oxide loss
Radiation and convection loss
Sensible heat loss in fly ash
Sensible heat loss in bottom ash
Mill reject loss
Heat credits (As Negative Loss)
INDIRECT METHOD
ADVANTAGES DISADVANTAGES
1. Accuracy is more 1. More no of readings
2. Identifying the losses & correction 2. Capacity and output data can
to the losses area is possible not be checked.
3. The primary measurements (Fuel, 3. Some losses are practically
FG analysis & Temp) can be immeasurable and value
measured very accurately. must be estimated.
4. The resulting efficiency usually has
lower uncertainty because the measured
quantities (Losses) represents only a
small fraction of the total energy.
5. The effects of fairly substantial errors in
secondary measurement and estimated
values are minimal.
6. Permits corrections of test results to
standards or Guarantee condition.
Probable measurement errors and resulting errors in efficiency
calculation by Direct method:
Measurement Measurement error Error in Effy
Calibrated Flow Nozzle ±0.55 ± 0.55
Coal Scales ± 0.25 ± 0.25
HHV (Coal) ± 0.50 ± 0.50
(Oil & Gas) ± 0.35 ± 0.35
Reheat flow (By Calculation) ± 0.60 ± 0.10
SH Outlet Temperature ± 0.25 ± 0.15
RH In / Out Temperature ± 0.25 ± 0.10
FW Temperature ± 0.25 ± 0.10
SH Outlet Pressure ± 1.00 ± 0.00
RH In/Out Pressure ± 0.50 ± 0.00
Probable measurement errors and resulting errors in efficiency
calculation by Heat Loss Method:
Measurement Measurement error Error in Effy
HHV (Coal) ± 0.50 ± 0.03
(Oil & Gas) ± 0.35 ± 0.02
Orsat Analysis ± 3.00 ± 0.30
Exit Gas Temperature ± 0.50 ± 0.02
Inlet Air Temperature ± 0.50 ± 0.00
Ultimate Analysis
Carbon ± 1.00 ± 0.10
Hydrogen ± 1.00 ± 0.10
Moisture ± 1.00 ± 0.00
S umma ry of los s e s in a boile r
L2 Mois ture los s % 6.523
L1 Dry ga s los s % 5.542
L3 Combus tible los s % 1.453
13.518
L5 Ra dia tion los s % 0.270
L4 Air mois ture los s % 0.200
L6 S e ns ible he a t of a s h % 0.415
L8 Ca rbon monoxide los s % 0.065
L7 Mill re je ct los s % 0.049
0.999
L Tota l % 14.517
E Efficie ncy % 85.483
100 - L
S umma ry of los s e s in a boile r
controllable
L1 Dry ga s los s % 5.542
L3 Combus tible los s % 1.453
L8 Ca rbon monoxide los s % 0.065
L7 Mill re je ct los s % 0.049
7.109
un -controllable
L2 Mois ture los s % 6.523
L5 Ra dia tion los s % 0.270
L4 Air mois ture los s % 0.200
L6 S e ns ible he a t of a s h % 0.415
7.408
L Tota l % 14.517
E Efficie ncy % 85.483
100 - L
1. UNBURNT CARBON LOSS
Ash in coal A % 43.96
% Carbon in fly ash Cf % 0.56
Distribution of fly ash Df % 90
Combustibles in fly ash Uf Kg / kg coal 0.00223
Uf = Df/100 * A/100 * Cf / (100 - Cf)
% Carbon in bottom ash Cb % 3.26
Distribution of bottom ash Db % 10
Combustibles in bottom ash Ub Kg / kg coal 0.00148
Ub = Db/100 * A/100 * Cb / (100 - Cb)
Total combustibles U Kg / kg coal 0.00371
U = Uf + Ub
CV of Carbon CVc Kcal / kg 8077.8
GCV of coal Gcv Kcal / kg 3627.84
Unburnt carbon loss L_UC % 0.826
L_UC = U * CVc * 100 / Gcv
2. DRY GAS LOSS
Carbon in coal C % 34.32
Sulphur in coal S % 0.43
Total combustibles U Kg / kg coal 0.00371
Specific heat of gas Cp KJ / kg mol / °C 30.6
FG temp. at AH outlet Tg °C 138
Ref. air temp. Ta °C 43
CO2 % at AH outlet CO2_out % 14.5
CO % at AH outlet CO_out % 0.05
GCV of coal Gcv Kcal / kg 3627.84
Weight of dry gas per Kg of Wd Kg / kg mol 0.1953
"as fired fuel"
( C + S / 2.67 - 100 * U )
12 * (CO2_out + CO_out)
Sensible heat of dry gas Sh KJ / kg coal 567.64
Sh = Wd * Cp * (Tg - Ta)
Dry Gas loss L_G % 3.738
L_G = Sh * 100 / Gcv / 4.186
3. LOSS DUE TO MOISTURE IN FUEL
Total moisture in fuel M % 8
FG temp. at AH outlet Tg °C 138
Ref. air temp. Ta °C 43
GCV of coal Gcv Kcal / kg 3627.84
Sensible heat of water vapour Sw KJ / kg 2578.84
SW = 1.88 * (Tg - 25) + 2442 + 4.2 * (25 - Ta)
Loss due to moisture in fuel L_M % 1.358
L_M = M * Sw / Gcv / 4.186
4. LOSS DUE TO HYDROGEN IN FUEL
Hydrogen in coal H % 1.96
Loss due to hydrogen in fuel L_H % 2.997
L_H = 9 * H * Sw / Gcv / 4.186
5. LOSS DUE TO MOISTURE IN AIR
Carbon in coal C % 34.32
Hydrogen in coal H % 1.96
Sulphur in coal S % 0.43
Oxygen in coal O % 6.02
GCV of coal Gcv Kcal/kg 3627.84
Ambient temp. (dry) Td °C 40
Ambient temp. (wet) Tw % 32
Wt. of moisture Mwv Kg/kg air 0.0273
(from psychrometric chart)
Ref. air temp. Ta °C 43
FG temp. at AH outlet Tg °C 138
O2 % at AH outlet O2_out % 4.6
CO2 % at AH outlet CO2_out % 14.5
CO % at AH outlet CO_out % 0.05
N2 % at AH outlet N2_out % 80.84
N2_out = 100 - (O2_out + CO2_out + CO_out)
Stoichiometric air Sa Kg / kg coal 4.3702
Sa = (2.664*C + 7.937*H + 0.996*S - O) / 23.2
Excess air Ea % 26.743
Ea = (O2_out - CO_out/2) / [0.2682*N2_out - (O2_out - CO_out/2)] * 100
Total moisture in air Ma Kg / kg 0.1512
Ma = Sa * Ea * Mwv
Loss due to moisture in air L_mA % 0.178
L_mA = Ma * 1.88 * (Tg - Ta) * 100 / Gcv / 4.186
6. LOSS DUE TO CARBON MONOXIDE
CO2 in gas - AH out CO2_o % 12.2
CO in gas - AH out CO_o % 0.0085
Carbon in fuel C % 40.8654
CV of carbon monoxide CVco Kcal/kg 2415
Gross CV Gcv Kcal/kg 3620
Combustibles U Kg/kg of coal 0.005686
Loss due to carbon monoxide L_co % 0.044
L_co =CO_o*7*CVco*(C-100U)/3/(CO2_o+CO_o)/Gcv
7. RADIATION LOSS
Loss due to surface L_ß % 0.22
radiation and convection
(as per prediction based on ABMA curve)
8. LOSS DUE TO SENSIBLE HEAT IN FLY ASH
Temperature of fly ash Tg °C 138
Ref. air temp. Ta °C 43
Specific heat of fly ash Cpf Kcal / kg / °C 0.16
Ash in coal A % 43.96
Distribution of fly ash Df % 90
GCV of coal Gcv Kcal / kg 3627.84
Loss due to sensible heat in fly ash L_f % 0.166
L_f = A/100 * Df/100 * Cpf * (Tg - Ta) * 100 / Gcv
9. LOSS DUE TO SENSIBLE HEAT IN BOTTOM ASH
Temperature of bottom ash above ambient Tb °C 600
Specific heat of bottom ash Cpb Kcal / kg / °C 0.16
Ash in coal A % 43.96
Distribution of bottom ash Db % 10
GCV of coal Gcv Kcal / kg 3627.838
Loss due to sensible heat in bottom ash L_b % 0.116
L_b = A/100 * Db/100 * Cpb * Tb * 100 / Gcv
Heat Credits:
The heat crdits are generally the other heat inputs
then through / from the fuel. (eg. Heat due to shaft
power of pulverizer, Fans, etc. which are coming
inside the system boundary)
10. HEAT CREDIT
Total Mill power MP Kw 2475
Total PA Fan power Kw 956.25
Total coal flow Cflo T/hr 100.9
GCV of coal Gcv Kcal/kg 3627.84
Kw-hr / kg of fuel KwKg Kw-hr/kg 0.034006
KwKg = MP / Cflo / 1000
Heat credit (Heat Equivalent of Power) H_cr % -0.806
(as negative loss)
H_cr = KwKg * 859.86 * 100 / Gcv
Various Boiler Losses
By Gas Dry Gas Loss
Loss due to Moisture in Gas
Due to Fuel Moisture
Due to moisture formed by H2 in fuel
Due to air moisture
By Ash Unburnt carbon Loss
Sensible heat loss in Fly ash
Sensible heat loss in Bottom ash
Other Loss Carbon mono oxide Loss
Radiation Loss
Heat loss through Mill rejects
Heat Credit
Factors affecting Unburnt Carbon Loss
a) Design Factors
Type of fuel preparation system
Burner and Burning System
Residence time
b) Fuel Characteristics
Heating Value
Proximate Analysis
Ultimate Analysis
c) Operational facors
Coal Particle Size
Excess air
Primary air to coal ratio
Distribution of Secondary air
Burner Tilt
Air Temperature
Fa ctors Affe cting Dry Ga s Los s
1 Coa l
Mois ture
Ca rbon
Gros s CV
2 Air te mpe ra ture e nte ring AH
Ambie nt
S CAP H
3 Ga s te mpe ra ture
AH le a ka ge
AH e nte ring a ir te mpe ra ture
AH e nte ring ga s te mpe ra ture
Boile r loa d
FW te mpe ra ture
X ra tio of AH
Te mpe ring a ir
Air ingre s s
4 Ga s qua ntity
Exce s s a ir
AH le a ka ge
Factors Influencing Various
01. Dry Gas Loss
Losses
Flue Gas Temperature, Excess Air & Fuel Analysis
02. Loss Due To Moisture Formed From Hydrogen
Hydrogen Content In Fuel & Flue Gas Temperature
03. Loss Due To Fuel Moisture
Moisture Content In Fuel & Flue Gas Temperature
04. Loss Due To Air Moisture
Humidity Of Combustion Air, Excess Air Level & Flue
Gas Temperature
Factors Influencing Various
Losses
05. Radiation & Convection Loss
Insulation Of Boiler
06. Mill Reject Loss
Reject Rate & CV Of Reject
07. Unburnt Carbon Loss In Ash
Ash in Fuel & Unburnt Carbon In Fly / Bottom Ash
08. Sensible Heat Loss In Ash
Ash Temperature
Capac ity Re duc tio n in a Bo ile r
Fue l input
Low cv coa l
Milling ca pa city
Grinding ca pa city
Drying ca pa city
Ca rrying ca pa city
Drive ca pa city
Dra ught s ys te m
ID fa n limita tions
P re s s ure drops high
AH choking
Chimne y ba ck pre s s ure high
High volume
AH le a ka ge s
Duct le a ka ge s
High ga s te mpe ra ture s
Worn out impe lle rs
Me ta l te mpe ra ture s high
High s pra y re quire me nts
Fouling of s urfa ce s
METHODS OF REDUCTION OF
UNBURNT CARBON LOSS
• Good burner maintenance
• Ensuring consistent mill fineness
• Proper secondary air adjustment
• Reducing primary air to the minimum most possible
• Cutout oil support at higher loads where coal flame is
stable as oil preferentially deplete o2 in the area and
reduces ‘o2 ‘ for coal particles to burn
• Check coal property and tune combustion
• Keep boiler heat transfer surface clean so that losses can
be reduced thus reducing the coal input
UNBURNT CARBON LOSS
CAUTION
IT ALSO DEPENDS ON
• COAL PROPERTIES LIKE VOLATILE
MATTER AND FIXED CARBON TO
VOLATILE MATTER RATIO.
• FURNACE SIZE
• TYPE OF MILL AND FIRING SYSTEM
• SUPPLEMENTRY FUEL FIRING LIKE
BFG GAS ,COG GAS or COREX GAS
METHODS OF REDUCTION
OF DRY GAS LOSS
- CORRECT EXCESS AIR
- HIGH MILL OUTLET TEMP.
- ARRESTING AIR INGRESS
- AIR HEATER PERFORMANCE
- CLEAN SURFACES
- SEAL/COOLING/PURGE
AIR QTY. JUST REQD.
Flue Gas Temperature
Reduction methods
• Operate the boiler at correct excess air.
(Usually 20 % for coal)
• Cleanliness of boiler surfaces
• Good combustion of fuel
• Reduction of tempering air to mill.
• Reduction in air ingress
• Cleaning of air heater surfaces and
proper heating elements
Boiler Efficiency Calculation – Direct Method
(Input/Output Method)
Efficiency, E = Ho/Hi*100
Where,
Heat Input, Hi = CF * GCV*1000
Heat Output, Ho = {Qf*(Hs – Hf) + Qr*(Hro – Hri)}*1000
Where,
CF – CoalFlow; Qf – FW Flow quantity
Hs – SH Outlet Enthalpy; Hf – FW Enthalpy
Qr – RH Flow; Hro - RH Outlet Enthalpy
Hri - RH inlet Enthalpy
APH Performance (Code: ASME PTC 4.3)
APH Leakage in %, AL = (Wg – Wgi)*100 / Wgi
= (CO2_in – CO2_out)*90 / CO2_out OR = (O2_out – O2_in)*100 / (21 –
O2_out)
TgNL = AL / 100 * CpA / CpG*(Tgo – Ta) + Tgo
Gas side efficiency, Ef_G = (Tgi – TgNL)*100 / (Tgi – Ta)
X Ratio, XR = (Tgi – TgNL) / (Tao – Ta)
Tgc = {Tac*(Tgi – Tgo) + Tgi*(Tgo – Ta)} / (Tgi – Ta)
Where
Tgi & Tgo – Gas temperature entering & leaving APH
Ta & Tao – Air temperature entering & leaving APH
Tac – Design air temperature entering APH
TgNL – Calculated Gas temperature leaving APH corrected for No air leakage
Tgc – Corrected gas temp leaving APH for deviation from design entering air temp
CpA & CpG – Mean Specific heat of air and gas
Wgi & Wg – Quantity of wet gas entering & leaving APH
NOx Conversion:
NOx (in Kg/GJ) = NOx (in PPM) * 0.718 / 1000 * (21 – O2ref) / (21 – O2)
Performance Calculations
1. SH Spray Flow = FW Flow*(h_SHBS – h_SHAS) / (h_SHBS–h_SHSW)
2. RH Spray Flow = RH Flow*(h_RHBS – h_RHAS) / (h_RHAS–h_RHSW)
3. FC = SH Flow*(h_SH-h_FW) + RH Flow*(h_Rho-h_Rhi)*100
GCV*Efficiency
4. Excess Air = (O2i-COi/2)*100 / {0.2683*N2i-(O2i-COi/2)} or
O2/(20.9-O2)
Where,
FC – Fuel consumption
h_SHBS – Enthalpy at SH before spray
h_SHAS – Enthalpy at SH after spray
h_SHSW – Enthalpy of SH spray water
RH flow calculation
Reheater Flow, Qr = Qs – Qgl – Qex + Qrs
Where,
Qs – SH Flow; Qgl – Turbine gland leak flow
Qrs – RH spray flow; Qex – HP Heater 6 Extraction quantity
Qex = Qfw*(Hfwo – Hfwi) / (Hex – Hd)
Where,
Qfw – FW flow
Hfwi – Feed water HP heater 6 inlet Enthalpy
Hfwo – Feed water HP heater 6 outlet Enthalpy
Hex – HP heater 6 Extraction Enthalpy.
Hd – HP heater 6 Drain Enthalpy.
Proximate to Ultimate Conversion
Proximate Data (As fired) Sample
Total Moisture M % 8.00
Ash A % 42.60
VOLATILE MATTER VM % 21.60
FIXED CARBON FC % 27.80
GCV GCV Kcal/Kg 3800.00
Proximate Analysis (On M & Ash Free basis)
VM (M & Ash Free) VM' % 43.72
FC ( M & Ash Free) FC' % 56.28
VM'=VM*100/(100-VM-A)
Ultimate Analysis (On M & Ash Free basis)
Carbon C' % 79.43
C' = FC' + 0.9*(VM'-18)
Hydrogen H' % 5.41
H' = VM' * {7.35 / (VM'+10) - 0.013}
Sulphur S' % 1.00
Nitrogen N' % 1.58
N' = 2.1 - 0.012*VM'
Oxygen O' % 12.58
O' = 100 - (C' + H' + S' + N')
Ultimate Analysis
Carbon C % 39.24
Hydrogen H % 2.67
Sulphur S % 0.49
Nitrogen N % 0.78
Oxygen O % 6.22
C = C' * (100 - M - A) / 100
Moisture % 8.00
Ash % 42.60
100.00
[Link] Description Symbol Unit
1 Turbine Heat rate THR Kcal/KWHr 2000 2000 2000
2 Boiler Efficiency BE % 86 87 88
3 Change in Boiler Efficiency CBE % -1 0 1
4 Plant Heat rate PHR Kcal/KWHr 2325.58 2298.85 2272.73
(PHR = THR / BE *100)
5 Change in plant heat rate CPHR Kcal/KWHr -26.73 0.00 26.12
For 200MW Unit with 75% PLF
6 Units generated per year UG KWHr 1314000000 1314000000 1314000000
(UG = 200*24*365*0.75*1000)
7 Heat required per year HR Kcal 3.05581E+12 3.0207E+12 2.9864E+12
(HR=UG*PHR)
For coal of 4000 Kcal/Kg
8 Coal qty required CQ Tonnes 763953.4884 755172.414 746590.909
(CQ = HR / 4000 / 1000)
For coal cost of Rs.1000 / Ton
9 Total cost of coal CC Rs 763953488.4 755172414 746590909
(CC = CQ * 1000)
10 Change in cost CIC Rs -8781074.58 8581504.70
11 Change in cost per Unit Heat rate CICHR Rs 328500 328500
(CICHR = CIC / CPHR)
12 Change in cost per Unit Efficiency CICE Rs -8781074.579 8581504.7
(CICE = CIC / CBE)
13 Unit cost of power CP Rs 0.5814 0.5747 0.5682
(CP = CC / UG)
For 1 KW Auxiliary Power
14 Units lost per year UL 8760 8760 8760
(UL = 1*24*365)
15 Cost per year C 5093 5034 4977
(C = UL*CP)
Effe ct of boile r pa ra me te rs
on the rma l cycle
S H outle t pre s s ure
S H outle t te mpe ra ture
RH outle t te mpe ra ture
RH s pra y
S H s pra y
Blowdown
Auxilia ry S te a m
Effe c t o n Plant He at Rate
Due to Bo ile r Parame tars
Fo r a 500 MW unit
kca l/hr
10 ° C dro p in MS te mpe rature 9.6
10 ° C dro p in RH o utle t te mpe rature 6.6
1 % inc re as e in RH pr. dro p 3
(% o f inle t pr.)
De c re as e in thro ttle pre s s ure by 1 bar 1.2
S H s pray inc re as e by 1 % 0.6
RH s pray inc re as e by 1 % 6
Optimization of Boiler Efficiency
a) HHV All Losses
b) FG APH out Temp Dry gas, Sensible heat in Ash, H2, Fuel
and Air Moisture Loss
c) Excess air Dry gas, Unburnt & Air Moisture Loss
d) Fuel Moisture Fuel Moisture Loss
e) Air Moisture Air Moisture Loss
f) H2 in Fuel H2 Loss
g) Mill reject rate or GCV Mill reject Loss
Hence Major parameters to be looked into for Better Efficiency are
1. FG Temp
2. Excess air Level
3. Mill reject rate and
4. Unburnt carbon in ash
Control / Optimization of other parameters (i.e GCV, H2, Fuel moisture and Air
Moisture) are not possible.
Correction of Efficiency to Standard /
Guaranteed Condition.
Correction of Efficiency are done for Variation in
Following Factors
GCV of Fuel
H2 in Fuel
Total Moisture in Fuel
Ambient temperature and
Humidity of air.
BOILER AUXILIARIES
-INDUCED DRAFT FAN
- FORCED DRAFT FAN
- PULVERIZER MILLS
- PRIMARY AIR FAN
-SEAL/PURGE/COOLING/
IGNITOR AIR FAN
- LUBRICATION OIL SYSTEMS
MAJOR REASONS OF INCREASE
IN AUXILIARY POWER
CONSUMPTION ARE
• OPERATION OF UNIT WITH HIGHER
EXCESS AIR
• AIR INGRESS IN BOILER
• AIR HEATER LEAKAGE
• HIGHER PA FAN OUTLET PRESSURE
• COAL PULVERIZATION TOO FINE
• PLUGGAGE IN LINE
FACTORS AFFECTING AUXILIARY P OWER
ID FANS
AH LEAK
GAS TEMP ERATURE
DUCT LEAKAGES
EXCES S AIR
LOAD/ P LANT HEAT RATE
DRAUGHT LOS S
AH CHOKING
FD FANS
AH LEAK
WIND BOX P R.
EXCES S AIR
LOAD/ P LANT HEAT RATE
P RES S URE LOS S
AH CHOKING
S CAP H CHOKING
P A FANS
AH LEAKAGE
P A HEADER P R.
MILL AIR FLOW
P RES S URE LOS S
AH CHOKING
MILL
COAL QTY.
GCV
LOAD/ P LANT HEAT RATE
COAL
MOIS TURE
HGI
COAL FINENES S
MILL CONDITION
SOURCES OF AIR INGRESS
(MEMBRANE WALL BOILER)
• FURNACE ROOF
• EXPANSION JOINTS
• AIR HEATERS
• DUCTS
• ESP HOPPERS
• PEEP HOLES
• MANHOLES
• FURNACE BOTTOM
TUBULAR AIR HEATER
• CLEANING OF TUBES
• REPLACING OF DAMAGED TUBES
• PROPER DISTRIBUTION OF GAS
AND AIR
ROTARY AIR HEATERS
• PROPER BASKETS
• CLEANLINESS OF BASKETS
• PROPER SEAL SETTING
HIGHER PA OUTLET
PRESSURE
• INCREASES AIR HEATER LEAKAGE
RESULTING IN HIGHER ID FAN
LOADING
• INCREASES PA FAN POWER
CONSUMPTION
• MAINTAIN ADEQUATE PRESSURE
EXCESS MILL FINENESS
• REDUCES MILL CAPACITY
• INCREASES MILL WEAR
• INCREASE MILL AND PA FAN
POWER
• MAY NOT IMPROVE COMBUSTION
METHODS TO REDUCE AUXILIARY
POWER
- OPERATE UNIT AT CORRECT AIR FLOW
- AIR INGRESS REDUCTION
- AIR HEATER MAINTENANCE
- OPTIMUM FAN OPERATION
- RUN MIN. NO. OF MILLS REQD.
- PULVERIZER TO OPERATE AT CORRECT
AIR FLOW AND PULVERIZED COAL
FINENESS
- IMMEDIATELY ATTEND FUEL, AIR,
WATER AND STEAM LEAKAGES.
TYPICAL HEAT LOSS
UNIT DADRI SING EID
MW 200 500 16
CARBON LOSS 0.827 0.364 0.52
DRY GAS LOSS 4.325 4.847 5.320
FUEL H2 LOSS 3.609 3.520 6.57
FUEL MOISTURE 2.129 2.814 15.99
LOSS
OTHER LOSSES 1.001 0.726 0.44
TOTAL LOSS 11.711 12.071 28.84
FUEL COAL COAL BAGASSE
