Bottom & fly ash final ppt

Bottom and fly ash of boiler

1. Bottom Ash & Fly Ash Unburned DEEPAK PATEL ACB ( India) Ltd .

2. Definition & where we are? Expected COAL ASH: A collection of residual produced during the combustion of coal. BED ASH: The heavier portion of coal ash that settles on the furnace of the boiler. FLY ASH: A light form of coal ash that floats in the flue gas. It will be carried various stages. UNBURNED: In bottom and fly ash the coal which is not completely take part in combustion is termed as unburned. Coal ash Bed ash Fly ash

3. Definition & where we are? Expected COAL ASH: A collection of residual produced during the combustion of coal. BED ASH: The heavier portion of coal ash that settles on the furnace of the boiler. FLY ASH: A light form of coal ash that floats in the flue gas. It will be carried various stages. UNBURNED: In bottom and fly ash the coal which is not completely take part in combustion is termed as unburned.

4. Unit # 1 Unit # 2 Fly ash 75% Fly ash 60% Bed ash 25% Bed ash 40% Coal ash Coal ash

5. Unit # 1 Unit # 2

6. Unit Ash Design Value (%) Actual Value (%) Expected (%) 1 Fly 4 5.56 5 2 Fly 3.275 3.55 3.4 1 Bed 0.2 0.32 0.2 2 Bed 2.175 6 5

7. Cost benefits Unit # 1 Unit # 2 Coal ( M.Ton )/day 1024 800 Ash(% / M.Ton ) 58 / 593.92 51/408 Pri ce of coal 450 450 Bed Ash 148.48 163.2 Fly ash 445.44 244.8 % of Carbon in coal 30 30

8. Unit Ash Actual Losses from design value (%) Expected Target (%) 1 Fly 1.56 0.56 2 Fly 0.275 0.15 1 Bed 0.12 0.12 2 Bed 3.825 1

9. Actual losses Total Unburned Carbon =17.23728 M.Ton /Day Total Coal Losses = 68.94912 M.Ton /Day Unburned Carbon( M.Ton /day Unit # 1 Unit # 2 Bed Ash 0.178176 9.43704 Fly Ash 6.948864 0.6732 Total 7.12704 10.11024 Coal Losses ( M.Ton /day) Unit # 1 Unit # 2 Bed Ash 0.712704 37.74816 Fly Ash 27.79546 2.6928 Total 28.50816 40.44096

10. Actual losses Total Cost =1,13,24,893 Rs. Expected Target Total Cost = 30,69,399 Rs. (Cost/Year) Unit # 1 Unit # 2 Bed Ash 1,17,061.6 62,00,135 Fly Ash 45,65,404 4,42,292.4 Total 46,82,465 66,42,428 (Cost/Year) Unit # 1 Unit # 2 Bed Ash 1,17,061.6 10,72,224 Fly Ash 16,38,863 2,41,250.4 Total 17,55,924 13,13,474

11. Contributors Ratio of Air Flow as per design (U#1 146 ton) (U#2 150 ton) Design calorific value of coal (U#1 2250) (U#2 2700) Furnace Draft As per design(U#1 -5mmwc) (U#2 -15mmwc)

12. Impact analysis Actual cost, Unit #1 Bed ash= 29,072.25 Rs. Fly ash= 11,41,537.5 Rs. Unit #2 Bed ash= 6,40,575 Rs. Fly ash = 1,37,970 Rs. Total ash cost per year =19,49,154.75 Rs. Expectation to reduce cost, Unit #1 Bed ash= 29,072.25Rs. Fly ash= 4,10,625Rs. Unit #2 Bed ash=1,67,535 Rs. Fly ash =75,390 Rs. Total ash cost per year =6,82,622.25 Rs.

13. Listing out Major contributor Air Ingress Furnace Draft Proper Combustion Bed Nozzle Coal Distribution Nozzles Size of Coal

14. Time bound action plan total Payback period Unit Target/ Date for optimization Cost saving 1 0.2% / 5% ( 30 th September 2018 ) 17,55,924 Rs. 2 5 % / 3.4% ( 30 th April 2017) 13,13,474 Rs.

15. Actual Expectation Percentage Reduce

16. Resources requirement with cost implication No. Resources Cost/Nos. Total 1. Bed Nozzle(Unit # 1) 200 Rs. 1131200/2 2. Bed Nozzle (Unit # 2) 1000 Rs. 615000 3. Coal Spreading plate 12000 Rs. 384000 Total

17. THANKS !