Monitoring Prediction Of Fouling In Coal Fired

Literature Review

Discuss About The Monitoring Prediction Of Fouling In Coal Fired.

Fouling is considered to a technical term which defines the accumulation of the unwanted materials on the heat transfer surfaces. This type of materials are either living or non-living substances. This is generally distinguished from the other type of phenomenon related to the growth of the surface, which generally occurs upon the components surface, system or the performance of a function which has been explained and useful. Business this the fouling process is associated with impeding or interfering with all this functions. Fouling on the boilers is generally dependent upon the type of boiler that is being used and also upon the design and the fuel that is being fired. The fouling is different in many ways in different type of boilers (Ikechukwu 2014).

Despite of the various causes the actual nature of deposit consists of extra resistance in the process of transferring heat which is generally presented which is responsible for reducing the capability of the operations which the heat exchanger is having. Due to the accumulation of various kind of unwanted materials inside the pipes, machines or the heat exchanges, different kind of problem arises in the liquid bearing systems. This acts as a major reason which interferes the function of the entire system.  The fouling factor helps in determining the rate of fouling and in this vital role is played by the temperature (Chen et al. 2012). This kind of deposition also gives rise to different kind of difficulties in the fluid bearing system which would be having an effect upon the total performance negatively upon the plant which initially causes a lower production capacity along with high maintenance cost.

According to some of the investigations conducted by some of the researchers upon fouling discusses about the various types of depositions and also the possible causes as well as the resulting problems (Low et al. 2015). Besides this other researchers have been associated with investigating the mechanisms and the technologies that are available for the purpose of preventing the deposition problems in the boilers by making use of the soot blowers, ash behavior prediction tools, and many more.

Gutierrez et al. has been associated with developing a model which is completely dynamic. The model is prepared which is generally dependent upon the mass along with the energy and the balances present in the momentum which is done by making use of the constitutional equations (Ortiz 2011). Besides two parts has also been divided in the fire-tube boilers and this includes “the fire/gas side” and “the water/steam side”. In the beginning a non-liner model has been prepared which is followed by reducing it so as to shorten the computational time management this has been associated with providing a reasonable result. This might be allowing the simulation of the processes along with the design which is a multivariable controller (Li et al. 2012). Simulations acts as a very useful tool for the training as well as for providing assistance during online decisions (Williamson 1994).

Research Questions, Aim, and Sub-goals

According to Kumar et al. pressure vessels are generally associated with working under a particular pressure as well as under a particular temperature. Besides this they also are associated with containing lethal substances which acts as a hazardous element for both humans as well as for animals and the entire environment (Kumar and Kumar 2014). Various kind of design codes have prepared along with being developed for the purpose of having an assured minimal amount of safety standards. Various type of calculations can be applied to the software for the purpose of finishing the design of the pressure vessel as quickly as possible. The study has been associated with investigating a particular section of the parameters design. Besides there also exists several other parameters which are not generally considered and this mainly includes the “wind loads”, “thermal loads”, “fabrication methods”, “erection load”, “seismic load”, “transportation load” and  and many more (Lawrence et al. 2008). But despite of all this overcoming of the insufficiency can be achieved by the process of mastering software. Use of the graphical based software has been done for the purpose of making the Mechanical design of pressure vessel.

According to Ganan et al. the installation of thermal power are associated with emitting different types of matter which are responsible for polluting the atmosphere which acts as the main reason lying behind the greenhouse effect and is also responsible for harming the entire environment. The major pollutants which are emitted to the atmosphere due to the use of these equipment mainly includes the Sulphur Oxide (SO2), Hydrocarbon (HC), Carbon monoxide (CO), Carbon dioxide (CO2), and Nitrogen Oxides (NOx). Because of high pollution due to all these type of gases, various agencies responsible for looking after the environment have been associated with imposing certain maximum levels of emission (Ganan et al. 2005). There exists an origin of each pollutants which has been emitted in the resulting gases during the process of combustion. From the combustion of the gases three fundamental elements can be found and this includes the “fuel”, “comburent” and “activation energy”.

The research questions that this paper tries to answer mainly includes the following:

Q1. How can Fouling be reduced?

Q2. What are the general materials required for eliminating the fouling effect?

Q3. How the efficiency of the boilers can be increase?                 

In this research the optimum operating conditions are to be evaluated of the two three-stage pirotubular boiler which are to be connected parallel by making use of the gasoil C. The main of this research is to develop the entire system by considering the operating variables which are generally present in the injection pressure and the number of burners that are to be used.

Theoretical Content

The main goal of this research is to reach the highest level of efficiency by studying the optimal operating conditions that the three-stage pirotubular boiler is having. Another goal of this work includes the least amount emissions from the boiler which are harmful to the environment. The operations of the boiler are to be analysed by means of altering the variables which are generally allowed during the process of installation and this mainly includes the pressure related to injection and the number of burners that are to be used, besides this it is also to be noted that both of this are responsible for modifying the flow of mass independently.

Fire-tube boiler are generally considered to be a boiler in which the gases which are hot comes from the burner passes through single or multiple tubes and are generally responsible for running through the water containers which are sealed. Followed by this the heat of the gases is transferred through the walls of the tubes which is generally done by the process of thermal conduction, which initially leads to the heating of the water and this initially creates a steam (Hansen and Blankinship 2006). The fire-tube boiler are generally associated with developing one third of the four major historical types of boilers which mainly includes the “low-pressure tank“, “flued boilers with one or two large flues”, “haystack” boilers, “fire-tube boilers with many small tubes”, and “high-pressure water-tube boilers”. The cylindrical tank that is to be used might be horizontal or vertical in shape. A conceptual physical geometry needs to be developed for the process of designing the fire-tube steam boiler along with making necessary calculations and from this the dimensions and other deductions can also be estimated, and lastly, there is a need of developing a working drawing, which is associated with analyzing with software (Wac?awiak and Kalisz 2012). There are several researchers who are associated with working on the fire tube boiler and also on the efficiency.

The experiment would be consisting of two three-stage peritubular boiler having the thermal power of 465 KW. This includes the mono-block boilers which are generally made by making use of the foils made of steel and are generally isolated by making use of the fiber glass having the thickness of around 70mm. the boilers would be equipped with a control panel which would be having two thermostats. This thermostats are associated with regulating the working tie for each of the burner for the gasoil C which would be having the maximum viscosity of around 6cSt to 20 ⁰C. Along with this there would be existing two time counters which would be associated with registering the number of operating ours for each of the burner (Mahajan, Patil and Attarde 2018). For the purpose of handling the system in case of failure of the one system there exists a temperature gauge and a pressure gauges along with a safety thermostat.

• This would be suitable for operating with the pressurized as well as with the negative pressure combustion chambers.
• Would be consisting a mechanical spraying system which is having high-pressure.
• Would be having an automatic combustion chamber purge prior to the lighting of the boiler.
• There would be a control panel that which would associated with displaying the operations of the burner.
• Presence of an automatic air controller at each and every stage.
• The air would be controlled by making use of the hydraulic system which would be associated with allowing of the purging of the burner by having an open and closed air condition. This would be mainly done during the periods when no firing takes place and this generally done so as to prevent the entry of air in the combustion chamber (Dai et al. 2015).

All this boilers are connected parallel by making use of a circuit which is having a closed nature and in this the circulation of water takes place through the pressure of working and this varies from 1.5 to 2.0 kg/cm². The safety valve would be adjusted to a value of around 3kg/cm². The operations of this boilers are semi-automatic and would be having the capability of regulating the air for each and every level of the power. All this regulations would be conducted by making use of the hydraulic system which is turn is associated with allowing the blocking of the supply of air during the halting phase (Hare, Rasul and Moazzem, 2010). Besides this it would also be responsible for the pre-evacuation of the gases which are present in the channels and this would be done before the ignition takes place. Initially this would be associated with facilitating the start-ups due to the fact that the combustion process becomes rich in oxygen.

The operations of the combustion chamber generally occurs in the partial vacuum and due to this reason after the initiation of the combustion process the whole process would be leading to the expelling of the gases in its own atmospheric pressure (Patiño et al. 2016). Along with this the circuit of the gas would be consisting of three phases amongst which two would be present in the fire place and the other one would be present in the exhaust tubes. Along with this circuit would be would be consisting of a tubular bunch where it is seen that the fumes are associated with circulating in the turbulent flow. This in tur enhances the transmission of heat. There exists a horizontal exit in the plenum chamber which is associated with facilitating the cleaning of the tubular sheaf along with the combustion chamber (Ohijeagbon et al. 2013). For the purpose of making estimations related to the installation of efficiency, the composition of the fumes was determined in relation to the “air excess coefficient” (λ) , “the losses for unburned gases in the exhaust fumes” (qi), “the losses for the sensible enthalpy” (qA), and lastly the “temperature of the exit” (TH). All this data would be gathered by making use of the TESTCO mode 300 M-I analyzer. The probe of this analyzer was placed in the exit fumes from the boiler (Dai et al. 2015). The equations provided below shows the different way by which the various parameters can be calculated.

Equation 1:

In the (CO₂) _Max is generally considered to be the specific rate that is maximum and has the capability of getting liberated, and the number 21 represents the oxygen percentage in the air and the O₂ is generally considered to be the value of oxygen.

Equation 2:

 The combustion process’s efficiency is generally dependent upon the decrease that the heating fuel is having which has been estimated.

Equation 3:

The Sieggert calculation is to be used for the purpose of calculating the losses by making use of the sensible heat of the fumes and would be expressed in % which would be generally regarding the reduction in the heating which has been estimated.

Equation 4:

The above equation shows the way by which the excess air coefficient can be calculated. The (O₂) _Max is considered to be the specific O₂ which is generally liberated by means of the fumes, along with this the A_real is considered to be the rate of real air flow which is presented in the boiler. The A_min is generally considered to be the air flow rate which is minimum and is essential for the purpose of burning the fuel.

Equation 5:

The equation above shows the way of calculating the velocity of the fumes.

Equation 6:

The equation above shows the way of calculating the volumetric flow rate of the fumes. There occurs a change in the color followed by the darkening of the functions of the residual concentration. The reading would be continued by comparing this with the Bacharach scale that is from 0 to 9. The variables of the operation are generally considered along with the pressure in the injection and the amount of burners (Pan et al. 2012). By making use of this variables numerous possible combinations were carried out for the purpose of optimizing the process of combustion as one of the task of the pressure as well as the quantity of burners that are used.

After completion of the experiment it has been seen that the maximum efficiency that is boiler is having has been obtained for one of the burner at a pressure of around 9kg/cm² with an efficiency of around 95%. In the two burners the outmost efficiency has been obtained at a pressure of around 12 kg/cm² having a value of around 93%. Besides this it is also possible to represent the percentage variation of O₂ versus the injection pressure. In case when one of the burner is considered then the losses related to the unburned gases general decreases and this generally happens due to the increase in the injection pressure. The similar thing happens for both of the burners used in the boiler. The main reason lying behind the reduction in the unburned gas is due to the increase in the injection pressure which thereby increases the fuel flow and the temperature of the fire place which thereby decreases the unburned gases.

Conclusion:

The experiment has been associated with evaluating the conditions of the three-stage peritubular boilers which are connected in a parallel way. Fouling is considered to be a phenomenon which is extremely complex and the main reason lying behind this is the existence of numerous variables which are having an adverse effect on the boilers. The information which has been predicted is very much helpful for the purpose of reducing the problems due to the fouling in the boilers. The elimination of this problem is not possible but this can be reduced to minimum amount which would be helping a lot in savings in the power plants. Along with this it is also seen that the there are several fouling materials which shows higher rate of deposition than any of the other type of materials. The information which has been predicted has been associated with reduction of the problems related to fouling. The most efficient way by which the fouling can be eliminated is by the prevention of the ingress of the species of fouling in the circuit responsible for the cooling of the water.

References

Chen, Q., Finney, K., Li, H., Zhang, X., Zhou, J., Sharifi, V. and Swithenbank, J., 2012, ‘Condensing boiler applications in the process industry’, Applied management, vol. 89, no. 1, pp.30-36.

Dai, B.Q., Wu, X., De Girolamo, A. and Zhang, L., 2015, ‘Inhibition of lignite ash slagging and fouling upon the use of a silica-based additive in an industrial pulverised coal-fired boiler, Part 1, Changes on the properties of ash deposits along the furnace’, Fuel, vol. 139, pp.720-732.

Dai, B.Q., Wu, X., De Girolamo, A., Cashion, J. and Zhang, L., 2015, ‘Inhibition of lignite ash slagging and fouling upon the use of a silica-based additive in an industrial pulverised coal-fired boiler: Part 2, Speciation of iron in ash deposits and separation of magnetite and ferrite’, Fuel, vol. 139, pp.733-745.

Ganan, J., Al-Kassir, A., González, J.F., Turegano, J. and Miranda, A.B., 2005, ‘Experimental study of fire tube boilers performance for public heating’, Applied thermal engineering, vol. 25, no. 11-12, pp.1650-1656.

Hansen, T. and Blankinship, S., 2006, ‘Infrared camera performs double duty’, Power Engineering, vol. 110, no. 7, pp.88-90.

Hare, N., Rasul, M.G. and Moazzem, S., 2010, February, ‘A review on boiler deposition/foulage prevention and removal techniques for power plant’, In Recent Advances in Energy and Environment. Proceedings of the 5th IASME/WSEAS International Conference on Energy & Enviroment (EE’10) vol. 23, pp. 25.

Ikechukwu, G.A., 2014, ‘Fabrication of Pilot Multi-Tube Fire-Tube Boiler Designed For Teaching and Learning Purposes in Mechanical Laboratory’, In Proceedings of the World Congress on Engineering vol. 2.

Kumar, V. and Kumar, P., 2014, ‘Mechanical design of pressure vessel by using PV-ELITE software’, International Journal of Scientific and Research Publications, vol. 4, no. 4, pp.1-4.

Lawrence, A., Kumar, R., Nandakumar, K. and Narayanan, K., 2008, ‘A Novel tool for assessing slagging propensity of coals in PF boilers’, Fuel, vol. 87, no. 6, pp.946-950.

Li, J., Brzdekiewicz, A., Yang, W. and Blasiak, W., 2012, ‘Co-firing based on biomass torrefaction in a pulverized coal boiler with aim of 100% fuel switching’, Applied Energy, vol. 99, pp.344-354.

Low, F., De Girolamo, A., Wu, X., Dai, B. and Zhang, L., 2015, ‘Inhibition of lignite ash slagging and fouling upon the use of a silica-based additive in an industrial pulverised coal-fired boiler: Part 3–Partitioning of trace accounting’. Fuel, vol. 139, pp.746-756.

Mahajan, P.G., Patil, S.P. and Attarde, D.V., 2018, Combustion Chamber of Boiler to Generate Tornado Effect.

Ohijeagbon, I.O., Waheed, M.A., Jekayinfa, S.O. and Opadokun, O.E., 2013, ‘DEVELOPMENTAL DESIGN OF A LABORATORY FIRE-TUBE STEAM BOILER’, Acta Technica Corviniensis-Bulletin of Engineering, vol. 6, no. 1, p.147.

Ortiz, F.G., 2011. Modeling of fire-tube boilers, ‘Applied Thermal Engineering’, vol. 31, no. 16, pp.3463-3478.

Pan, Y., Si, F., Xu, Z., Romero, C.E., Qiao, Z. and Ye, Y., 2012, ‘DEM simulation and fractal analysis of particulate fouling on coal-fired utility boilers’ heating surfaces’, Powder technology, vol. 231, pp.70-76.

Patiño, D., Crespo, B., Porteiro, J. and Míguez, J.L., 2016, ‘Experimental analysis of fouling rates in two small-scale domestic boilers’, Applied Thermal Engineering, vol. 100, pp.849-860.

Skea, A.F., Bott, T.R. and Beltagui, S.A., 2002, ‘A comparison of mineral fouling propensity of three coals using a pilot scale under-fed stoker combustor’, Applied thermal engineering, vol. 22, no. 16, pp.1835-1845.

Su, S., Pohl, J.H., Holcombe, D. and Hart, J.A., 2001, ‘Slagging propensities of blended coals’, Fuel, vol. 80, no. 9, pp.1351-1360.

Teruel, E., Cortes, C., Diez, L.I. and Arauzo, I., 2005, ‘Monitoring and prediction of fouling in coal-fired utility boilers using neural networks’, Chemical Engineering Science, vol. 60, no. 18, pp.5035-5048.

Wac?awiak, K. and Kalisz, S., 2012, ‘A practical numerical approach for prediction of particulate fouling in PC boilers’, Fuel, vol. 97, pp.38-48.

Williamson, J., 1994, ‘The Impact Of Ash Deposition On Coal Fired Plants’ Proceedings of the Engineering Foundation Conference Held at the St. John’s Swallow Hotel, Solihull, England, CRC Press.