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Solid Fuel Firing Systems<br />

and Components


<strong>Hitachi</strong> <strong>Power</strong> <strong>Europe</strong><br />

From Coal to Electricity<br />

d<br />

b<br />

f<br />

c<br />

e<br />

a<br />

Generation of electricity in a typical coal power plant<br />

Contents<br />

<strong>Hitachi</strong> <strong>Power</strong> <strong>Europe</strong> 2<br />

Selection Criteria 5<br />

Furnace 6<br />

Mill Feeders 8<br />

Pulverizers 10<br />

Pulverized Fuel Burners 14<br />

Burn-Out Grate 20<br />

Ash Removal Systems 21<br />

Replacement Parts Service 23<br />

A Before being injected into the furnace, the raw coal is crushed down to a fine pulverized form<br />

in the coal mills.<br />

2 Flue gases up to 1,450 °C arise from pulverized fuel combustion in the steam generator furnace.<br />

The liberated heat is used to generate high-pressure and high-temperature steam.<br />

3 The steam is directed to a turbine; it flows onto the blade wheels and turns the turbine shaft.<br />

An attached generator then generates the electrical power.<br />

4 With the help of catalysts, the nitrogen oxides in the flue gas react in the DeNO x system<br />

to produce nitrogen and water vapor.<br />

5 Ash particles adhere to electrically-charged surfaces in the electrostatic precipitator;<br />

they are rapped and removed from the flue gas.<br />

6 In the flue gas desulphurization system (FGD) lime slurry or suspended pulverized limestone<br />

bind the sulphur dioxide coming from the flue gas. The final product arising is gypsum.<br />

2


Technology Leader with Excellent References<br />

Whether as a plant constructor or as a supplier of key components, <strong>Hitachi</strong> <strong>Power</strong> <strong>Europe</strong><br />

<strong>GmbH</strong> (HPE) is one of the technology and market leaders in fossil-fired power plants.<br />

The company – a subsidiary of <strong>Hitachi</strong>, Ltd. – has its head offices in Duisburg. HPE designs<br />

and builds not only power plants but also supplies all the key components such as utility<br />

steam generators, environmental engineering, turbines and pulverizers. In so doing, HPE can<br />

turn back to a track record going back over many years, an extensive list of references and<br />

to the outstanding know-how of its workforce. Within the <strong>Hitachi</strong> Group, HPE is responsible<br />

for the markets in <strong>Europe</strong>, Africa, Russia (incl. Belarus) and India.<br />

<strong>Hitachi</strong> <strong>Power</strong> <strong>Europe</strong> <strong>GmbH</strong>, Duisburg<br />

Babcock Fertigungszentrum <strong>GmbH</strong>, Oberhausen<br />

BGR Boilers Private Ltd., Chennai<br />

Donges SteelTec <strong>GmbH</strong>, Darmstadt<br />

1 2<br />

6<br />

4<br />

7<br />

<strong>Hitachi</strong> <strong>Power</strong> Africa (Pty) Ltd., Johannesburg<br />

<strong>Hitachi</strong> <strong>Power</strong> <strong>Europe</strong> Service <strong>GmbH</strong>, Duisburg<br />

Meeraner Dampfkesselbau <strong>GmbH</strong>, Meerane<br />

3<br />

5<br />

Coal Firing Systems 3


Firing Systems and Components<br />

Ensuring Economic Efficiency, Conserving Resources<br />

As one of the global cutting-edge companies in power plant design and construction,<br />

<strong>Hitachi</strong> <strong>Power</strong> <strong>Europe</strong> provides highly advanced firing systems which can be used in their<br />

entirety or as single components for practically all fossil fuel qualities.<br />

Project Country Kunde MW Fuel Order obtained<br />

Niederaußem Germany RWE Energie AG 1 x 1,012 Lignite 1995<br />

Boxberg Q Germany VEAG 1 x 907 Lignite 1995<br />

Elbistan B Turkey TEAS 4 x 360 Lignite 1998<br />

Dezhou 5 / 6 China CNTIC 2 x 660 Anthrazit 1998<br />

Hamborn Germany RWE Energie AG 1 x 260 Blast Furnace Gas 1999<br />

Iskenderun Turkey Siemens / STEAG 2 x 660 Hard Coal 2000<br />

Neurath F & G Germany RWE Rheinbraun AG 2 x 1,100 Lignite 2003<br />

Baosteel China Baoshan Iron & Steel Co. Ltd 1 x 350<br />

Blast Furnace Gas, Coke<br />

Oven Gas, Heavy Fuel Oil<br />

2005<br />

Boxberg R Germany Vattenfall <strong>Europe</strong> 1 x 670 Lignite 2005<br />

Walsum 10 Germany Evonik 1 x 790 Hard Coal 2006<br />

Moorburg A / B Germany Vattenfall <strong>Europe</strong> 2 x 820 Hard Coal 2006<br />

Datteln Germany E.ON Kraftwerke 1 x 1,100 Hard Coal 2006<br />

Gent Belgium Electrabel 1 x 300 Blast Furnace Gas 2006<br />

Medupi South Africa Eskom 6 x 790 Hard Coal 2007<br />

Maasvlakte Netherlands E.ON Kraftwerke 1 x 1,100 Hard Coal 2008<br />

Wilhelmshaven Germany Electrabel 1 x 750 Hard Coal 2008<br />

Kusile Südafrika Eskom 6 x 790 Hard Coal 2008<br />

Rotterdam South Africa Electrabel 1 x 790 Hard Coal 2008<br />

Maja India NTPC 2 x 660 Hard Coal 2012<br />

Solapur India NTPC 2 x 660 Hard Coal 2012<br />

Raghunathpur India NTPC 2 x 660 Hard Coal 2012<br />

Kozienice Poland Enea 1 x 1,000 Hard Coal 2012<br />

Selection of steam generator orders since 1995<br />

HPE develops solutions, which are just as flexible as our customers’ requirements, for energy<br />

suppliers and industry alike. This can be seen most clearly from the large number of different<br />

types of references (see table) available. A high degree of operational efficiency and conservation<br />

of resources /environment is looked upon as an obligation and challenge by HPE in<br />

designing and manufacturing new utility steam generators. This also applies to the modernization<br />

and enhancement of existing power plants and their components, such as pulverizers<br />

and burners.<br />

It goes without saying that HPE as a certificated DIN ISO 9001 company always orientates<br />

itself to the best possible quality.<br />

4


What Counts is the Choice<br />

The planning and design of firing systems is primarily dependent on the fuel used and<br />

must be individually tailored – something requiring above-average achievements on the<br />

part of our designers.<br />

Whilst there is no secret about up-to-date firing systems, one still needs considerable<br />

know-how and a long track record in plant concepts and specific sequences. Playing a prime<br />

role here are the fuel properties themselves, such as calorific value, moisture and ash content,<br />

volatiles and coal grindability.<br />

Advanced firing systems with a staged combustion sequence lower emissions and require<br />

substantial design and material selection outlay on the basis of the standards and legislation<br />

in force. This applies equally to the selection and construction of the firing components.<br />

Tangential firing system<br />

Slag-tap firing system<br />

Cyclone firing system<br />

U/double U firing system<br />

Hard coal<br />

Dry bottom ash<br />

firing system<br />

Normal volatile coal<br />

Low volatile coal<br />

Front firing system<br />

Double front firing system<br />

Opposed firing system<br />

Corner firing system<br />

Double front firing system<br />

Opposed firing system<br />

Lignite<br />

Dry bottom ash<br />

firing system<br />

Direct firing system<br />

Direct firing system<br />

with vapor separation<br />

Direct firing system<br />

with vapor recycling<br />

Biomass<br />

Dry bottom ash<br />

firing system<br />

Direct firing system<br />

Indirect firing system<br />

Coal Firing Systems 5


Furnace<br />

Pulverized Hard Coal Firing System<br />

The principal features are:<br />

■■<br />

Uniform liberation of heat<br />

■■<br />

Low nitrogen oxide emissions<br />

coupled with practically a total<br />

fuel transformation<br />

■■<br />

Oxygen-rich flue gas atmosphere<br />

right next to the boiler tube walls<br />

Fossil-fired power plants are currently enjoying a boom across the world. And hard coals,<br />

in particular, can be widely used for energy transformation purposes.<br />

The decision to design a firing system with dry bottom ash removal or as a slag-tap furnace<br />

largely depends on the fuel properties themselves. Volatile matter, ash content and chemical<br />

ash composition have always been of decisive significance.<br />

The decision-making process was simplified with the launching of innovative DS ® burners<br />

followed by tremendous combustion stability. Modern steam generators are usually designed<br />

today solely as dry ash discharging boiler plants at low cost and high efficiencies. This applies<br />

to practically the entire range of fuels irrespective of their effects from high volatile bituminous<br />

coal to anthracite.<br />

For many years now, the linear arrangement as front, double-front or opposed firing equipment<br />

complete with vertically offset burner levels has proved to be the most suitable system<br />

for pulverized hard coal firing systems.<br />

The clear arrangement of mill and burner level ensures that the highly complex systems are<br />

clearly designed and arranged. This, in turn, creates a high degree of accessibility and ease<br />

of maintenance.<br />

CAD model of the Datteln 4<br />

utility steam generator<br />

■■<br />

1 x 1,100 MWel / 1 x 2,939 t/h<br />

■■<br />

Benson ® Steam generator<br />

■■<br />

Hard coal<br />

■■<br />

Steam parameters:<br />

Superheated steam: 600 °C / 305 bar;<br />

Reheater: 620 °C / 78 bar<br />

■■<br />

Entering into service: 2011<br />

■■<br />

Scope of delivery:<br />

Utility steam generator including<br />

all the related components, engineering,<br />

installation and commissioning<br />

6


Pulverized Lignite Firing System<br />

Combustion systems for lignite operated steam generators can be designed as direct<br />

systems for the use of raw lignite or as combined systems using raw and pre-dried lignite<br />

in the same furnace.<br />

Even with the usage of very high ash lignites, the new HPE lignite swirl burners (RS ® burners)<br />

do not need any vapor separation.<br />

The excellent igniting stability of the RS ® burners allows the burners to be arranged in a<br />

different way at the combustion chamber – for instance in the form of an all-wall firing system.<br />

Such a system combines the benefits of linear firing equipment with those of a tangential<br />

firing system. The firing steps alone enable the 200 mg/m 3 NO x standard to be undercut in<br />

RS ® burners. As a result, there is no need for complex, multiple air-staging concepts for<br />

adherence to the NO x standards.<br />

The stable ignition of RS ® burners produces a marked improvement in the percentage load<br />

operations of lignite firing systems. Even with problematical fuels, the excess stoichiometric<br />

operation of these burners has a positive effect on fouling and slagging and it optimally<br />

protects the evaporator tube walls from corrosive flue gas products.<br />

The future will see boiler plants mainly being planned for the use of dry pulverized lignite with<br />

interim storage.<br />

CAD model of the Boxberg R<br />

utility steam generator<br />

■■<br />

1 x 670 MWel / 1 x 1,710 t/h<br />

■■<br />

Benson ® Steam generator<br />

■■<br />

Lignite<br />

■■<br />

Steam parameters:<br />

Superheated steam: 600 °C / 315 bar;<br />

Reheater: 610 °C / 72 bar<br />

■■<br />

Entering into service: 2010 / 2011<br />

■■<br />

Scope of delivery:<br />

Utility steam generator including<br />

all the related components, engineering,<br />

installation and placing into service<br />

Coal Firing Systems 7


Mill Feeders<br />

Belt conveyor<br />

Reliability even under Demanding Requirements<br />

Designed as coal bunker dischargers, the mill feeders supply the pulverizers with raw coal –<br />

evenly dosed and in keeping with boiler load requirements.<br />

Even under very demanding requirements, the <strong>Hitachi</strong> <strong>Power</strong> <strong>Europe</strong> designed mill feeders<br />

operate both reliably and safely.<br />

Experienced HPE staff establish the optimum feeder in keeping with the requested fuel quantity,<br />

design directives (including DIN EN 12952-9, NFPA 85 F) and customer requirements<br />

(for instance, volumetric and gravimetric metering).<br />

Other selection factors are the various bulk material properties, such as coal flow and erosion<br />

behavior. The belt speed is determined by the quantity conveyed. Purge air is supplied to the<br />

housing to stop condensate forming and, in turn, to stop corrosion.<br />

8


In hard coal boiler units, belt conveyors are used to discharge the raw coal from the<br />

bunker. In lignite plants, drag-chain conveyors together with belt conveyors are used to<br />

discharge the raw coal from the bunker.<br />

Belt conveyor<br />

The belt conveyor with corrugated edge belt ensures high outputs, uniform bunker discharge<br />

and continuous mill charging – even under low conveying rates. This design permits volumetric<br />

/ gravimetric metering and quantities conveyed of up to 120 t/h. Conveyed material falling<br />

to the bottom of the feeder is transferred to the coal downcomer by the simultaneously running<br />

scraper chain.<br />

Raw coal<br />

d<br />

a<br />

g<br />

A Bed depth limiter<br />

B Belt drive station<br />

b<br />

h<br />

c<br />

C Belt tensioning station<br />

D Corrugated edge belt<br />

E Scraper chain<br />

F Lower belt supporting roller<br />

e<br />

f<br />

G Bunker shut off gate<br />

H Conveyor-type weigher (optional)<br />

Drag-chain conveyor<br />

Drag-chain conveyors are meant for limited conveyed quantities of up to approx. 40 t/h –<br />

this can, in special cases, be raised to 70 t/h. The fuel is discharged opposite to the direction<br />

of conveying. The drag-chain conveyor principle allows both a compact design with minimum<br />

spacing between bunker discharge and conveyor dumping as well as a possible large<br />

spacing between material charging and dumping.<br />

Raw coal<br />

e<br />

a<br />

d<br />

b<br />

c<br />

A Bed depth limiter<br />

B Belt drive station<br />

C Tensioning station<br />

D Forged fork link chain<br />

E Bunker shut off gate<br />

Coal Firing Systems 9


Pulverizers<br />

Excellent Results<br />

In the mills, the raw coal is simultaneously pulverized, dried and evenly distributed to the<br />

coal burners. Hot air or flue gases transfer the pulverized fuel to the burner and reduce the<br />

moisture in the coal.<br />

MPS ® Mill<br />

MPS ® Bowl & Roller Mill<br />

The MPS ® bowl & roller mill from <strong>Hitachi</strong> <strong>Power</strong> <strong>Europe</strong> grinds and dries hard coals and<br />

difficult-to-grind lignite with a low moisture content to pulverized fuel and distributes them<br />

evenly directly to the burners.<br />

Various-sized mills for throughputs ranging from 10 t/h to 200 t/h can be supplied. Constant<br />

refinements and impro vements have led to excellent crushing results with high fineness<br />

a<br />

b<br />

grades from raw coal found throughout the world. The positive operating<br />

properties and low energy requirements have contribu ted in no small<br />

measure to the success of these mills.<br />

c<br />

e<br />

g<br />

f<br />

d<br />

A Rotary classifier<br />

B Classifier drive<br />

C Grinding rollers<br />

E Grinding table<br />

F Gear<br />

G Motor<br />

D Hydro-pneumatic system<br />

10


Long Service Life<br />

RKD Mill<br />

RKD Tube Ball Mill<br />

The <strong>Hitachi</strong> <strong>Power</strong> <strong>Europe</strong> RKD tube ball mill grinds and dries difficult-to-pulverize hard coals<br />

(particularly low-volatile coals such as lean coal and anthracite). This mill type can deal with<br />

approx. 150 t /h of coal. Depending on size and space, the tube ball mill can be designed<br />

with drum or neck bearing and be of the single or double pass type.<br />

a<br />

g<br />

b<br />

d<br />

e<br />

c<br />

f<br />

A Rotary classifier<br />

B Oversize return<br />

C Neck bearing<br />

D Drive gear rim<br />

E Grinding ball filling<br />

F Feed spiral conveyor<br />

G Classifier riser<br />

Coal Firing Systems 11


Pulverizers<br />

Low Energy Requirements<br />

Pulverizing lignite is particularly challenging in view of its high moisture content and the<br />

considerable throughputs involved. Here again <strong>Hitachi</strong> <strong>Power</strong> <strong>Europe</strong> has the right products<br />

in this segment.<br />

DGS ® Mill<br />

DGS ® Integral Fan Distributor and Beater Mill<br />

HPE supplies DGS ® mills of various sizes up to a 180 t/h throughput for drying and pulverizing<br />

raw lignite and brown coals with a high moisture content.<br />

DGS ® technology involves the raw coal and flue gases being initially put through the precrushing<br />

beater section of the beater wheel. This ensures excellent air and coal dust distribution<br />

into the beater wheel. Crushing in the DGS ® mill is usually so<br />

intensive that adequate grinding fineness can be obtained in one<br />

a<br />

working operation – without the need of an additional classifier.<br />

c<br />

This both raises the pressure balance and cuts back on energy<br />

f g<br />

b<br />

g<br />

d<br />

requirements. The DGS ® mill has stood the test of time particularly<br />

with difficult-to-work lignites – something that explains<br />

its considerable lifetime and unrivalled properties.<br />

e<br />

A Flue gas gate valve<br />

B Inlet housing<br />

C Beater shaft<br />

D Beater wheel<br />

E Coupling<br />

F Motor<br />

G Bearing<br />

12


Easy Maintenance<br />

NV Mill<br />

NV Wet Coal Fan Mill<br />

The NV mills ranging from 10 t/h to 140 t/h throu ghputs are for crushing high moisture<br />

content lignites for direct injection into the furnace.<br />

Together with the flue gases, the raw lignite is brought for crushing purposes into the beater<br />

wheel. It acts as a fan impeller fitted with beater plates. Baffle-type classifiers ensure that the<br />

a<br />

e<br />

required fuel fineness for combustion is fulfilled.<br />

The high-tech NV mill more than meets the ongoing demands<br />

worldwide of operational availability and low costs.<br />

f<br />

g<br />

b<br />

c<br />

d<br />

A Gate valve housing<br />

B Grinding chamber door<br />

C Grinding chamber<br />

D Beater wheel<br />

E Baffle-type classifier<br />

F Double bearing<br />

G Motor<br />

Coal Firing Systems 13


Pulverized Fuel Burners<br />

Optimum Combustion<br />

How do you lower NO x emissions and at the same time control as many different fuels as<br />

possible Questions like these are today determining the concept of pulverized fuel firing<br />

systems and burners.<br />

DS ® Burners<br />

300<br />

1,800<br />

1,667 1,697<br />

260<br />

1,607<br />

1,487<br />

1,600<br />

250<br />

1,303<br />

1,400<br />

200<br />

1,095 1,119 1,135 1,165<br />

1,200<br />

184<br />

144<br />

859<br />

1,000<br />

150<br />

879 9591,031 787<br />

138<br />

120 120<br />

800<br />

643<br />

120<br />

100<br />

88<br />

600<br />

383<br />

80<br />

72 72<br />

64<br />

46<br />

60 400<br />

263<br />

50<br />

8 9 9 129<br />

175<br />

20<br />

24<br />

16 30 30<br />

200<br />

8 1 0<br />

0 0 0<br />

0 0<br />

1991 1993 1995 1997 1999 2001 2003 2005 2007 2009 2011 2013 2015<br />

n Total number n Year of commissioning<br />

DS ® burners were introduced early in the 1990s and continuously developed over the years.<br />

The burner’s principle is focused on fuel treatment to prepare the particles for the pyrolysis<br />

and ignition process that follows. The characteristic features of this burner type are expressed<br />

by the definition of initiation and course of ignition.<br />

Ignition = Pyrolysis + Oxidation<br />

This type of burner with a concentric design and swirled flow streams in all sections, has its<br />

field of application mostly in direct firing systems using all kinds of pulverized fuels.<br />

The DS ® burner concept utilizes operating experience from more than 1,100 applications.<br />

Pulverized Fuel<br />

Core Air<br />

Secondary Air Tertiary Air<br />

Adjustable<br />

Swirlers<br />

Fuel Nozzle<br />

Igniter<br />

14


DS ® burners with an operating range of 1: 3,5 are available for direct operated combustion<br />

systems in a range of thermal capacities from 20 to 100 MW.<br />

Fuels<br />

Burner Classes (MW thermal capacity)<br />

20 40 60 80 100<br />

Lignite* x x x<br />

Sub-bituminous coal x x x x<br />

Bituminous coal x x x x x<br />

Anthracite x x x<br />

Biomass (co-firing with coal) x x x x<br />

Biomass (standalone) x x<br />

* Pulverizer operation on air basis<br />

DS ® burner design for a windbox arrangement<br />

Basically developed for bituminous coal, these burners are applicable now for all carbon<br />

containing solid fuels like anthracite, sub-bituminous coal, lignite and biomass of different<br />

structures. The DS ® burner is suitable for applications with individual air control as well as for<br />

the use in common windboxes.<br />

Coal Firing Systems 15


Pulverized Fuel Burners<br />

DST Burner<br />

The DST burner has been developed on the basis of the DS ® burner concept for use in<br />

indirect firing systems.<br />

Core Gas Secondary Gas Tertiary Gas<br />

Pulverized Fuel<br />

Oil Lance<br />

Swirler<br />

Fuel Nozzle<br />

This burner type is the right one for pre-dried pulverized fuels like anthracite, bituminous and<br />

sub-bituminous coal, lignite, peat, biomass of various types as well as further carbon-containing<br />

pulverized fuels separately or in any combination. Dust loading can range from 0.5 up<br />

to 15 kg fuel / kg medium.<br />

DST burners can be used for atmospheric operation or in pressurized systems with air and / or<br />

oxyfuel atmosphere.<br />

Air, inert gas and flue gas with or without oxygen enrichment can be used as the transport<br />

medium for the fuel.<br />

DST burners can be operated with a turndown rate up to 1:17. As a result a boiler can be<br />

operated from lowest start-up load up to full load conditions with an unlimited load response<br />

rate. Due to an extremely high PF / PA ratio the NO x emission rate is rapidly reduced.<br />

DST burners are available for thermal capacities from 20 to 60 MW for all kinds of pre-dried<br />

pulverized fuels used in indirect firing systems.<br />

Fuels<br />

(pre-dried & pulverized)<br />

Burner Classes (MW thermal capacity)<br />

20 40 60<br />

Lignite x x x<br />

Sub-bituminous coal x x x<br />

Bituminous coal x x x<br />

Anthracite x x x<br />

Biomass (standalone) x x x<br />

16


DS ® burner direct (left)<br />

DST burner indirect (right)<br />

Comparison of both burner systems<br />

5<br />

Coal / PA Ratio [kg/kg]<br />

4<br />

3<br />

2<br />

1<br />

0<br />

Burner control range (as tested)<br />

Indirect firing system, DST burner<br />

Indirect firing system, DST burner<br />

Direct firing system, DS ® burner<br />

minimum load range<br />

0 5 10 15 20 25 30 35 40 45<br />

Burner capacity [MW]<br />

Energy storage and plant flexibility are the main challenges of power generation in the future.<br />

With the DST burner control range of 1:17 coal firing systems will be best prepared to meet<br />

the resulting operating demands.<br />

Coal Firing Systems 17


M<br />

M<br />

M<br />

M<br />

M<br />

M<br />

M<br />

M<br />

M<br />

M<br />

M<br />

M<br />

Pulverized Fuel Burners<br />

DST Burner<br />

Combined firing system<br />

M<br />

M<br />

100 %<br />

75 %<br />

M 20 M 40 M 30 M 10<br />

50 %<br />

M M M M<br />

M<br />

25 %<br />

Flexible Load Range<br />

0 %<br />

Flexibility is what is demanded of power generation now and in the future. With development<br />

of the DST burner, flexible concepts using indirect firing systems are now becoming the focus<br />

of interest.<br />

This system offers lots of advantages like:<br />

■■Turn down of investment and operating costs<br />

■■Independency of mill and boiler operation<br />

■■Wide load range with all burners in service<br />

■■Quick response in case of high load change demand<br />

■■Boiler operation without supplementary fuel (oil/ gas) – even for start-up<br />

■■Exact definition of burner air ratios that enable boiler excess air below 10 %<br />

The combined firing system using the advantages of the direct and indirect systems is the<br />

consequential answer to the fascinating questions surrounding coal fired power plants in<br />

facing the challenges of the future.<br />

18


RS ® Burner<br />

70 160<br />

60<br />

50<br />

40<br />

30<br />

20<br />

10<br />

0<br />

4<br />

4<br />

4<br />

0<br />

10<br />

6<br />

10<br />

0<br />

16<br />

6<br />

16<br />

48<br />

64<br />

76 76<br />

12<br />

100 100 100 100 100 100 100<br />

0<br />

0 0 0 0 0 0 0 0<br />

1994 1996 1998 2000 2002 2004 2006 2008 2010<br />

24<br />

124<br />

24<br />

124<br />

n Total number n Year of commissioning<br />

142<br />

18<br />

2012<br />

140<br />

120<br />

100<br />

80<br />

60<br />

40<br />

20<br />

0<br />

RS ® Burners<br />

Orders since 1994<br />

The extensive findings acquired from developing DS ® burner technology (flame stability, ignition<br />

as well as air staging in the burner proximate zone) are also available for lignite firing<br />

technology purposes.<br />

What has been developed is the lignite RS ® burner. In contrast to the conventional jet burner,<br />

the RS ® burner permits control of the fuel / air mixture and flame propagation in the burner<br />

proximate zone.<br />

Secondary Air<br />

Radiant<br />

Shielding Pipe<br />

Pulverized Fuel<br />

Cooling Air<br />

Secondary Air Deflecting Cone<br />

Coal Dust<br />

Coal Firing Systems 19


Burn-Out Grate<br />

High Efficiencies<br />

In lignite coal or peat-fired plants with a high proportion of xylitol or fibers in the fuel,<br />

the proportion of unburnt residue in the boiler hopper ash can be extremely high and this<br />

impairs firing efficiency.<br />

Burn-out grate diagram<br />

a<br />

Ash<br />

n b c<br />

f<br />

d<br />

A Boiler furnace hopper<br />

e<br />

B Refractory jacket of retarded<br />

combustion reactor<br />

C Water seal gasket<br />

D Firmly fixed grate supporting bars<br />

g<br />

E Grate carriage<br />

F Grate surface<br />

G Hydraulic system for grate<br />

carriage and deashing flap<br />

H Ash hopper<br />

I Cooling and combustion air<br />

J Deashing flap<br />

i<br />

h<br />

j<br />

k<br />

l<br />

K Ash discharge chute<br />

L Shutoff gate valve in ash<br />

discharge chute<br />

M Deasher<br />

m<br />

N Monitoring system<br />

The optimum designed burn-out grate ensures that the ash burnout in the boiler hopper is<br />

improved to over 80 % – thus substantially raising the overall efficiency of the boiler plant.<br />

In addition, afterburning results in additional heat input into the boiler hopper, which would<br />

otherwise be relatively cold. This leads to an even distribution of temperature in the furnace.<br />

20


➞➞<br />

Ash Removal<br />

Stable in the Extreme and Long Lasting<br />

Ash removal systems have been part of HPE’s range of production and supplies for many<br />

years now. This applies to bottom ash removal as well as to the transfer of ash accumulating<br />

in the course of air heater and electrostatic precipitator ash removal.<br />

Submerged scraper conveyor<br />

Submerged scraper conveyor functions:<br />

■■<br />

Air sealing to the boiler hopper<br />

■■<br />

Ash cooling<br />

■■<br />

Ash conveying<br />

■■<br />

Inlet for furnace inspection<br />

Submerged scraper conveyor for hard coal-fired systems<br />

e<br />

c<br />

a<br />

b<br />

i f<br />

h<br />

1 Bottom ash<br />

i<br />

f<br />

k g j k d k g<br />

Submerged scraper conveyor for lignite-fired systems<br />

c<br />

a<br />

k g j k d k g<br />

k<br />

e<br />

h<br />

2 Transfer chute with immersion piece<br />

3 Expansion joint<br />

4 Submerged scraper conveyor<br />

5 Drive station frequency controlled<br />

6 Tensioning station<br />

7 Idler stations<br />

8 Discharge chute<br />

9 Cooling water inlet<br />

J Overflow<br />

K Travelling rails<br />

Conveying<br />

direction<br />

Coal Firing Systems 21


Other Ash Removal Systems<br />

HPE provides a broad range of ash handling systems. These systems apply to ash handling<br />

for furnace bottom ash removal and also to the ash removal from all downstream ash<br />

accumulation points.<br />

Our systems offer a lot of benefits: they are stable in the extreme, wear parts are long lasting<br />

and both the energy requirements and operating / upkeep costs are low. HPE provides the<br />

entire range for utility steam generators with pulverized hard coal and lignite firing: from design,<br />

manufacturing and erection up to commissioning the complete ash disposal systems<br />

including loading systems for transport by truck, rail and ship.<br />

Ash Removal<br />

Components<br />

Our Other<br />

Ash Removal Systems<br />

■■Ash silos and dewatering bunker<br />

■■Single-strand chain conveyors<br />

■■Apron conveyor<br />

■■Screw conveyors<br />

■■Single and double roller crushers<br />

■■Hammer crushers<br />

■■Rotary feeders<br />

■■Single and double pendulum flap<br />

■■Shut off gates<br />

■■Ejectors<br />

■■Bucket-type conveyors<br />

■■Sluice ways<br />

■■Dry mechanical ash removal systems<br />

■■Hydraulic ash removal systems<br />

■■Pneumatic ash removal systems<br />

■■Mill reject systems<br />

■■Re-cooling systems for submerged<br />

conveyor overflow water<br />

22


Replacement Parts Service<br />

As a designer and manufacturer of original components, HPE is the ideal partner to contact<br />

when modernization or replacement parts are needed.<br />

Our extensive expertise derived from designing and delivering utility steam generators with<br />

the associated components over many years enables our HPE experts to provide professional<br />

solutions matched to customer requirements in the matter of plant design and operations.<br />

Optimized plants ensure that performance and availability are raised and that efficient operations<br />

are attained as far as possible. As a competent and flexible partner, HPE’ expertise is<br />

available in the fields of process engineering, plant optimization, measuring technology, plantinternal<br />

inspection, component installation and commissioning. At the same time, HPE supports<br />

customers in the design and configuration of their future plants – from the technical<br />

point of view (planning, design, optimizing) and in the matter of operating economy analyses.<br />

Rapid Service from<br />

a Competent Partner<br />

Feeders<br />

conveyor<br />

Coal Mills<br />

Burners<br />

Ash submerged<br />

scraper conveyor<br />

Manufacturing from<br />

a single source<br />

Belts<br />

Wear parts<br />

Pulverized fuel<br />

line elbows<br />

Chains<br />

As stakeholder in Babcock Fertigungszentrum<br />

<strong>GmbH</strong> in Oberhau-<br />

Chains Linings Pulverized fuel lines Scraper bars<br />

sen, we are in the closest possible<br />

Drives Nozzle rings Impact plates Wear plates<br />

contact with our partners and, as<br />

such, are flexible and quick in<br />

Bearings Shaft seals Housings Drives<br />

handling your enquiries and can<br />

Gate valves<br />

Conveyor-type<br />

weighers<br />

Feeding screw<br />

conveyors<br />

Beater sections<br />

Adjusting mechanisms<br />

Bearings<br />

provide you with dependable solutions.<br />

More on this under:<br />

www.bfz-ob.de<br />

Expansion joints<br />

Gear units<br />

Drives<br />

Service Hotline: +49.203.8038-2550<br />

Service Fax: +49.203.8038-612550<br />

Email: spareparts@hitachi-power.com<br />

Coal Firing Systems 23


© <strong>Hitachi</strong> <strong>Power</strong> <strong>Europe</strong> <strong>GmbH</strong> / 02.2013 / Printed on chlorine-free bleached paper<br />

<strong>Hitachi</strong> <strong>Power</strong> <strong>Europe</strong> <strong>GmbH</strong><br />

Schifferstraße 80<br />

47059 Duisburg, Germany<br />

Phone +49.203.8038-0<br />

Fax +49.203.8038-1809<br />

infobox@hitachi-power.com<br />

www.hitachi-power.com

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