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Research Papers: Energy Systems Analysis

Analysis of Fouling Degree of Individual Heating Surfaces in a Pulverized Coal Fired Boiler

[+] Author and Article Information
Paweł Madejski

EDF Polska S.A., Research and Development,
Ciepłownicza 1 St.,
Kraków 31-587, Poland
e-mail: Pawel.Madejski@edf.pl

Tomasz Janda

EDF Polska S.A., Research and Development,
Ciepłownicza 1 St.,
Kraków 31-587, Poland
e-mail: Tomasz.Janda@edf.pl

Jan Taler

Institute of Thermal Engineering,
Faculty of Mechanical Engineering,
Cracow University of Technology,
Al. Jana Pawła II 37,
Kraków 31-864, Poland
e-mail: Taler@mech.pk.edu.pl

Daniel Nabagło

EDF Polska S.A., Research and Development,
Ciepłownicza 1 St.,
Kraków 31-587, Poland
e-mail: Daniel.Nabaglo@edf.pl

Robert Węzik

EDF Polska S.A., Research and Development,
Ciepłownicza 1 St.,
Kraków 31-587, Poland
e-mail: Robert.Wezik@edf.pl

Magdalena Mazur

EDF Polska S.A., Engineering,
Ciepłownicza 1 St.,
Kraków 31-587, Poland
e-mail: Magdalena.Mazur@edf.pl

Contributed by the Advanced Energy Systems Division of ASME for publication in the JOURNAL OF ENERGY RESOURCES TECHNOLOGY. Manuscript received December 13, 2016; final manuscript received September 7, 2017; published online October 17, 2017. Assoc. Editor: Wojciech Stanek.

J. Energy Resour. Technol 140(3), 032003 (Oct 17, 2017) (8 pages) Paper No: JERT-16-1503; doi: 10.1115/1.4037936 History: Received December 13, 2016; Revised September 07, 2017

The paper presents the method of fouling degree evaluation of the heating surfaces in pulverized coal-fired boiler during coal combustion and biomass co-combustion. The fouling processes have a negative impact on the boiler operation by reducing the steam outlet temperature, increasing the mass flow rate of cooling spray water, and may be the reason for overheating of the superheater (SH) tube material. This leads to a reduction of the boiler efficiency and can cause shortening of a lifetime as well as damage of boiler heat exchangers, in particular, the steam SH. The basis of fouling degree assessment method are the dimensionless coefficients, which represent current values of heat absorbed by an individual heat exchanger in comparison to the value for a clean surface. The coefficients are determined based on the calculated heat power of individual heat exchanger taking into account the adjustment resulting from the flue gas temperature inside a combustion chamber. The results of the analysis showed a significant reduction of the amount of heat absorbed by the convection SH during continuous boiler operation. The next important conclusion is a large increase of the heat amount transferred to the radiant SH, which may result in exceeding the permissible temperature of the tube material. The proposed method together with on-line monitoring system installed on the boiler is used to calculate the fouling degree of individual heating surfaces. Accurate monitoring of boiler heating surface conditions can be used to optimize soot blowers operation and finally to improve process efficiency.

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Figures

Grahic Jump Location
Fig. 3

Live steam superheater and characteristic points used in calculations

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Fig. 4

The first stage of superheater (SH1)

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Fig. 5

The second stage of superheater (SH2)

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Fig. 6

The third stage of superheater (SH3)

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Fig. 2

Ash deposits on boiler surfaces being an effect of slagging on combustion chamber wall (a) and fouling on the platen superheater tubes (b) and ECO tubes bundle (c)

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Fig. 1

Arrangement of heat exchangers in boiler OP-380

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Fig. 7

The calculated thermal power of ECO and measured water mass flow rate in period of operation with different load

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Fig. 8

The calculated thermal power and measured flue gas temperature as a function of measured feed water mass flow rate

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Fig. 9

Arrangement (a) and original view (b) of the slagging panel installed on the boiler wall

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Fig. 10

TPC computed for ECO

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Fig. 11

TPC computed for evaporator

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Fig. 12

TPC calculated for the first stage of superheater (SH1)

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Fig. 13

TPC calculated for the second stage of superheater (SH2)

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Fig. 14

TPC calculated for the third stage of superheater (SH3)

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Fig. 15

TPC calculated for the first stage of reheater (RH1)

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Fig. 16

TPC calculated for the second stage of reheater (RH2)

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Fig. 17

TPC calculated for the third stage of reheater (RH3)

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