boiler retrofit.pdf

7/28/2019 Boiler Retrofit.pdf

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COAL WATER MIXTURE


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BOILER RETROFIT TECHNOLOGY

FORCOAL WATER MIXTURE


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CONTENTEMISSION STANDARDFUEL : COAL WATER MIXTURETYPE OF BOILERRETROFIT OF BOILER

AIR EMISSION CONTROL SYSTEMCONCLUSION


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EMISSION STANDARD


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The Air Emission Standard from Distribution Facilities

CoalHeavy FuelOil (HFO)

Natural Gas Biomass Other

1 Total Suspended Particulate mg/N.m 320 240 - 320 320

2 Sulfur Dioxide (SO2) ppm 700 950 - 60 60

3 Oxides of Nitrogen: NOX (as No2) ppm 400 200 - 200 200

4 Carbon Monoxide (CO) ppm 690 690 - 690 690

Type of Fuel

UnitPollutantsNo.

Remark: 1. Reference Condition at 1 Atm or 760 mm.Hg at 25C (Dry Basis) with Excess Air at 50% or Excess Oxygen 7%2. Reference under notification of the Minister of Industry

3. Reference the air emission standards from distribut ion facilities on February 4, B.E. 2548 (2005)


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The Air Emission Standard from Electricity Generation Transmission

New Power Plant After January 31, B.E. 2539 (1996)

Coal Oil Natural Gas Biomass

1 Sulfur Dioxide (SO2) ppm

Power Plant Size < 300 MWe 640 640 20 60

300-500 MWe 450 450 20 60

> 500 MWe 320 320 20 60

2 Oxides of Nitrogen: NOX (as No2) ppm 350 180 120 200

3 Particulates mg/N.m 120 120 60 120

No. Pollutants UnitType of Fuel

Remark: 1. Reference Condition at 1 Atm or 760 mm.Hg at 25C (Dry Basis) with Excess Air at 50% or Excess Oxygen 7%

2. Reference under notification of the Minister of Industry

3. Reference the air emission standards from electricity generation transmission or distribution facilities on

September 28, B.E 2547 (2004)


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Source : Department of Industrial Work, MOI

INDUSTRIAL EFFLUENT STANDARD

Parameters Units Standard Values

pH - 5.5-9.0

Conductivity m/cm < 2,000

Total Dissolved Solid (TDS) mg/l < 1,300

Biochemical Oxygen Demand (BOD5) mg/l < 20

Chemical Oxygen Demand (COD) mg/l < 120

Suspended Solids (SS) mg/l < 50

Total Kjedahl Nitrogen (TKN) mg/l < 100


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Source : Ministry of Interior

NOISE STANDARD IN WORK PLACE

Noise Level: dBA Exposure Time: hours per day Remar k

104 Not allow

91 Less than 790 7-8

80 More than 8 Earplugs are need

incase of necessary

Distance 1.5m from

center of Machine


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FUEL : COAL WATER MIXTURE


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COAL WATER MIXTURE (CWM)

ULTRA CLEAN MICRONIZEDCOAL SLURRY

CWM FOR INDUSTRY


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CWM TECHNOLOGY

Technical ReliabilityCWM, a new and clean fuel, good fluidity and stability. It can be used an alternative fuel in

steam boilers for industrial boilers, such as traveling grate boiler to increase combustion efficiency.


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CWM TECHNOLOGY

Specification of Coal

Total Moisture 10 %

Inherent Moisture 2~3

Ash 5

Volatile Matter 39.9

Fixed Carbon 44.1

Gross Calorific Value 6,400 kcal/kg

Total Sulfur 0.7

Hardgrove Grindability Index 46

Ash Fusion Temperature

Deformation 1,235 C

Hemispherical 1,305 C

Flow 1,360 C


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CWM CharacteristicsConcentration 65 1 %

Particle Size Distribution 45~50 m

Average Particle Diameter 250~300 m

< 75 m > 75 %

< 150 m > 93 %

iscosity 1,000 100 mPa.s

Ash 4 %

Low Calorific Value ~ 4,600 kcal/kg


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TYPE OF BOILER-

FIRE TUBE BOILER- WATER TUBE BOILER


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Source : SKG-CONDORKESSEL


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Economic Boiler(two-pass, dry back)Source : Spirax Sarco


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Source : Spirax Sarco

Fire Tube Boiler(three-pass, wet back)


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Thimble or Reverse Flame Boiler


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Water Tube Boiler


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Water Tube Boiler


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RETROFIT OF BOILER-

PARTIAL RETROFIT- FULL RETROFIT


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Source : DHMM Co.,Ltd.

CWM Boiler and Accessories


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Source : Idemitsu Kosan Co., Ltd.

CWM Burner: 11.5 tph


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1 Heat Evaporates Water

2 Volatile Matter liberates

3 Ignites4 Burns: Fixed Carbon blazes and Coke burns out

Four Stages for Combustion Process


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Proposed Retrofit

General layout still intact: Heating Surface Area almost same, varies a little

Arrangement of Burners: at the original Oil Burners, Capacity of Burners, Heating

Surface Area and Force Draught

Blast Distribution: complete Combustion, primary & secondary Force Draught Fan

Steam Generation: effective Utilizing and Operation

After Retrofit: Tear and Wear at Heating Surface Area must be carefully thought

over, especially at the Corners, Headers in hot Gas and also wear plate must be

improved

PARTIAL RETROFIT


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1 CWM Preparation: Storage Tank & CWM supply System2 CWM Burners & Accessories

3 Hearth Cool Ash Bucket, deslaging& dedusting Equipment

4 Precipitator: ESP, Bag Filter, etc.

5 Induced Draught Fan ( IDF )

6 Electricity & Control System

7 Structure & auxiliary Facilities


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No. Parameter Remar k

1 Main Equipment Load Screw Pump, Unload Screw Pumps, Pull-out Screw Pump,

Supply Screw Pumps, Magnetic Flowmeter, CWM Burners,

Mechanical Soot Blower, Air Compressor, Dedusting &

Deslaging System, Precipitator, IDF

2 Local Fabrication & Erection Work Unload Slot Tank, Storage Tank, Stirring Buckets, Slurry Filters,

Steel Frame, Platform, Staircase, Exterior Cover Sheet

3 Material & Labour Cost to ModifyCombustion Chamber of Boiler

4 Electricity & Control System

5 Civil & Construction Work by other


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Proposed Retrofit

CWM Preparation: Storage Tank & CWM supply System

Arrangement of CWM Burners & Accessories

Combustion Chamber Modification: Furnace Volume ( Height or Width ),Convection Surface Area, Analyze Structure of original of Boiler

Hearth Cool Ash Bucket, deslaging & dedusting Equipment

Precipitator: ESP, Bag Filter, etc.

Induced Draught Fan ( IDF ) Electricity & Control System

Structure & auxiliary Facilities

FULL RETROFIT


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NEW CWM BOILER

No. Parameter Remar k

1 CWM Unloading, Storage & Supply System Unload Slot Tank, Storage Tank, Load Screw Pump, Unload Screw Pumps, Pull-out Screw

Pump, Stirring Buckets, Supply Screw Pumps, Slurry Filters, Magnetic Flowmeter, etc.

2 CWM Boiler & Combustion System Steam Header, Water Cool Plate, Economizer, Steel Frame, Platform, Staircase, Exterior

Cover Sheet, Air Preheater, Superheater, Proper Pipeline, CWM Burners, Secondary Blast

Gate & Metal Elements of Chamber Wall, Primary Valve Instrument, etc.

3 Blower & Induced Draught Fan System FDF & IDF

4 Dedusting & Deslaging System, Precipitator Ash Removal System ( Bottom & Fly Ash)

5 Flue Gas, Ducting System & Insulation

6 Monitoring & Control System

7 Stack

8 Water Treatment Plant Softener, RO, Demineralization, etc.

9 Deaerator & Feed Water Tank, Feed Water Pumps &

Control Valves

10 Electricity System

11 Civil Work by other


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AIR EMISSION CONTROL SYSTEM


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Source : Flakt

ELECTROSTATIC PRECIPITATOR

Electrode System-Principle sketch


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The electric field in the dust layer


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Back-corona in the dust layer


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Collecting electrode-principle sketch


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Rapping acceleration distribution on the collecting electrodes


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Bag Filter

Source : EEC


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Source : EEC

HIGH EFFICIENCY BACKWASH PULSE-JET DUST COLLECTOR


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CONCLUSION


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Boiler Retrofit concerned with the regulation as follow:

Environmental Regulation:SO2,NO2,CO,Particulate,etc.

The air emission standard from distribution facilities utilizing coal shall beconsidered this notification.

Ambient Air Standard (1995)

Pollution Control Department (PCD)

Ministry of Natural Resources and Environment


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The air emission standard from distribution facilities on February 4, B.E. 2548

(2005 )

The air emission standard from electricity generation transmission or

distribution facilities on September 28, B.E. 2547 ( 2004 )

Department of Industrial Work

Ministry of IndustrySafety

Repair and Modification

Hydrostatic Test

Safety Technology Bureau

Ministry of Industry


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COST COMPARISON OF RETROFIT AND NEW BOILER

Parameter Retrofi t of Boiler Cost of Retrofit Cost Remar k

A Partial Retrofit Low Steam Generate drop 20% approximately

B Full Retrofit > 3 time of A Equivalent with existing HFO Boiler

C New Boiler 2 - 2.6 time ofA

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