Coal Test Burn Support  

Clyde Bergemann Anthony Ross offers test burn service to support, analyze and recommend boiler modifications for the customer

Clyde Bergemann Anthony Ross is pleased to provide service and support for customers that are looking at testing new coal blends.  Combustion experts from within the organization will conduct a comprehensive analysis and provide on-site support for the customer to ensure that all details of the test burn is captured and a full list of recommendations are provided.  Typical test burn support by Clyde Bergemann Anthony Ross will include the following items:

·          A preliminary evaluation of the coal quality of the existing coal at the plant and future coal

·          Working with the customer we provide a detailed protocol for the test burn. Specify and document required boiler operating parameters, operating condition and coal specification

·          Conduct the actual test burn with the existing coal and subsequently transferring over to targeted coal or coal blend

·          Collect all boiler data test results and provide a detailed report listing the findings and recommendation to burn the new coal.  Most data will be obtained from instrumentation and data logging currently existing at the plant.

In order to provide a full understanding of the coal and maximize the benefit to the customer, Clyde Bergemann Anthony Ross Company (CBARC) usually recommends that the test burn support to be divided into three tasks.

Printable Brochure (PDF)

TASK 1 – PRELIMINARY EVALUATION AND TEST PROTOCOL DEFINITION

A detailed test protocol will be submitted to the customer in preparation for the test burn.  The protocol will include a step by step procedure to blend the coal at varying ratios and information that should be collected.  A preliminary analysis will be done of the coal quality to determine the ratios of blend for the test burn.  The coal analysis conducted by CBARC would include looking at various constituents and ratios of mineral ash to determine slagging and fouling propensity.  The coal information would also help calculate efficiency and efficiency losses, ash loading analysis for the bottom ash and fly ash and pulverizer loading.  CBARC would also review the pulverizer performance and operating condition to establish an initial determination of the impact of changing coal quality on unit performance.  Based on this evaluation, CBARC will establish a test protocol which details the coal blends, operating condition and all necessary information that will be collected during the test burn.  In order to establish a concise test burn protocol, CBARC would typically request the following information from the customer during Task 1 execution. They include the following coal, operation and pulverization information:

·          Coal quality information including ultimate and proximate analysis, mineral ash analysis, heating value, Ash Fusion Temperature (AFT) analysis and Hardgrove Grindability Index (HGI) of both existing coal and new coal

·          Pulverization information including operating input and output temperatures and pressures, and coal fineness data

·          Unit operation condition, including the condition of the sootblowers, burners ash collection systems, significant events like mill puffs and/or explosions, and brief history of tube condition

·          Unit operations, such as O₂ setting, coal and air flow rates, flue gas flow rates, draft pressure, furnace exit gas temperature and economizer gas outlet temperature

·          Unit operations, steaming rates, pressures and temperatures at various locations inside the boiler

·          Emission information including CO₂, NO_x, Particulate Matter, SO_x, and CO

·          Ash analysis to determine Unburned Carbon levels and sampling locations.

CBARC realizes that some of this information may not be readily available however more information would establish a better representation for the unit current condition to establish a test burn protocol. Upon project acceptance, a detailed test log sheet will be submitted to the customer which outlines the information to be collected and submitted to CBARC in preparation to commence work on defining the test protocol.

TASK 2 – TEST BURN

A Senior Combustion Engineer from CBARC would oversee/support the execution of the new or blended coal test burn protocol at the plant for the full duration of the test.  The evaluation of the whole boiler by the CBARC Senior Engineer during the various phases of the test burn, as outlined by the test protocol will include but not limited to the following items:

·          A full evaluation of unit operating condition at each phase.  This includes documenting changes in operation condition of flue gas temperatures and pressures. Evaluation of steaming condition and subsequent changes during changes in coal

·          Detailed analysis of boiler condition including slagging and fouling at various locations, effectiveness of soot/wall blower operation including ash fusion, sintering and friability

·          Build a detailed slag map of the boiler to establish the location and operating effectiveness of the soot and wall blower blowers

·          Observe the fireball to determine color, impingement, pulsations or any other unusual conditions that may adversely impact boiler operation

·          Determine if the existing pendant openings are conducive to the fouling characteristics of the coal or if the pressure part spacing should be modified

·          Monitor and track pulverizer performance, including temperature and pressure, spillage and capacity issues

·          Monitor and track emission issues to determine combustion performance and constituents of the coal impacting emissions

·          Monitor fluid steaming rate and temperature thresholds at various location to avoid boiling in areas where boiling should be avoided

·          Track superheat steaming temperature, attemprator operations and changes in temperature distribution inside the boiler.

All the information from Task 2 will be compiled and summarized for the analysis and reporting period during Task 3.  During the test burn, we will work with the customer to take grab samples of the coal, pulverizer fineness and fly ash samples at predetermined frequencies to establish a snapshot of boiler operating condition during the test burn period. The customer will be requested to provide at least one individual from the plant to support this test.

TASK 3 - REPORTING

All the information compiled during the test burn will be analyzed and a detailed report will be generated highlighting the findings and a list of recommendations to potentially burn the new or blended coal.  The report will include the following items:

·          Details unit operation changes when burning new or blended coal including temperature and pressure of the flue gas

·          Details changes in unit steaming condition including temperature, pressure and distribution, any issues which would need to be addressed

·          Document any conditions that may arise to accelerate tube failure rates such as fly ash erosion and corrosion.

·          Highlight deposition areas and make recommendation on soot blower optimization and effectiveness both in location and frequency

·          Document emission issues that would be resultant of the coal quality

·          Make recommendation for operational changes to burn the new or blended coal

·          Make recommendation on pulverizer operating condition to maximize performance

·          Review the design of the pendant tube spacing and make recommendation on necessary changes in tube spacing and layout

·          Review ancillary equipment including the bottom ash and economizer hopper to determine their capacity and issues burning the coal

·          Identify the coal constituent that may restrict unit operation either due to slagging/fouling or emission

·          Other items that may be requested by the customer but are not listed.

For more information about Coal Test Burn Support Service, please contact us at (503) 641-0545 or email customerservice@anthonyross.com