NAACHIAR PAPER BOARDS PRIVATE LIMITED S. F. No. 352 & 353, Sevalpatti Village Near Vembakottai Sivakasi (Via) Tamilnadu, India

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1 Trial Report of PENTOMAG 2550 I (Coal Additive) NAACHIAR PAPER BOARDS PRIVATE LIMITED S. F. No. 352 & 353, Sevalpatti Village Near Vembakottai Sivakasi (Via) Tamilnadu, India 1

2 Ref: TCPL / NPBL / BRG PJV/ 0102 / Date: Tellabs Trial Report for PENTOMAG 2550 I - Coal Additive NAACHIAR PAPER BOARDS PRIVATE LIMITED S. F. No. 352 & 353, Sevalpatti Village Near Vembakottai Sivakasi (Via) Tamilnadu, India Prepared For: Mr. Sanjay H. Pandey Vice President (Technical) Prepared By: Bibek Ranjan Guha Sales Manager Mob: Coordinated By P. John Varghese Regional Manager Ramchandran Palani Area Manager T. Jeyaprakash Service Engineer TELLABS Chemicals Private Limited Kamanwala Chambers, Sir Phirozeshah Mehta Road, Mumbai , INDIA. Tel: +91 (22) Fax: +91 (22) TELLINE: (24 hr) Web Site: 2

3 1.0 Preface & Objectives of the Trial We are thankful to the management of Naachiar Paper Boards Pvt. Ltd., Sivakasi for giving us an opportunity to establish the performance of our additive PENTOMAG 2550 I in their 5 TPH Smoke Tube (Make: VPR), Coal fired Boiler. Our sincere thanks go to Mr. Sanjay H. Pandey Vice President (Technical) and the entire team of Boiler Engineers and Operators for timely guidance during the entire period of trial. We are also grateful to one and all, those who have helped us directly or indirectly in making this trial a success. The direct benefits are evident from the increase in Steam to Fuel ratio (Total Steam produced in Kg divided by total Coal consumed in Kg) after dosing our additive. It can be observed from the enclosed report that by using our additive, over all fuel savings of 7.36% is achieved, which amounts to an estimated net savings of Rs Lacs per annum, Objectives of the Trial: 1) Reduction of clinker / slag formation on grate and walls of combustion chamber of boiler. Acute clinkering / slagging hinder boiler operation, reduce boiler availability, increase maintenance cost etc. 2) Reduction of dark black smoke emission Naachiar Paper Boards was facing acute clinker formation problem along with acute dark black smoke emission problem. 3

4 2.0 Necessity of Coal Additive As you are aware, there is substantial amount of un burnt combustibles in the fly ash and bottom ash generated by any coal fired boiler. These un burnt combustibles consist mainly of Carbon particles. These Carbon molecules remain un burnt because of incomplete combustion in the fire box for lack of sufficient oxygen. To increase this oxygen availability in the firebox, a higher level of turbulence is required. But, with the increase in turbulence there will be an increase in dry flue gas quantity and corresponding heat losses. Even if the best of firing conditions are provided, there is still going to be enough avoidable combustibles to be concerned with because of cooling off of fly ash particles below ignition temperature due to extremely short time available for them in the fire box. The second problem is slagging, formation of hard (melted) deposits sticks to heating surfaces (evaporator, super heater, re heater) brick works or other elements inside the boiler. Loose ash deposits are not considered as slagging. When coal enters the furnace, most of the minerals in coal melt. The furnace is designed so that by the time the molten fly ash particles leave the furnace, they become solid. However only about 80% of the fly ash leaves furnace and rest falls down as bottom ash or in molten state deposits on the furnace wall tubes. These deposits are known as slag. Formation of slag leads to Loss of heat exchange balance (Resulting in steam and flue gas temperature pattern inside the boiler. In most cases there is increase of flue gas exit temperature and reduction in boiler efficiency.) Decrease in steam temperature after super heater and re heater creates problem for the turbine. To overcome the above mentioned problems, research has shown that a combustion optimising and anti slagging additive is the most economical and effective solution. 4

5 3.0 PENTOMAG 2550 I - Additive for Coal Fired Plant Coal additives have been used for several years, initially in powder form. Practical experience was however not satisfactory, first of all because of relatively high particle size of powder components. The smaller the particle the greater is the active surface. Pentol is the first manufacturer who developed production of fuel additives in form of stable slurry containing micronized active substances in oil suspension. Slurry is also resistant to water (powder will agglomerate in contact with moisture and its efficiency will be strongly limited). Also storage of additive in slurry form is easier and dosing is more precise. PentoMag 2550 I is an additive to optimize coal combustion and to prevent coal slagging (fouling). The term "slagging" is understood as formation of hard, sticky deposits covering evaporator and super-heater heat exchange tubes inside the furnace. Usually the slagging starts on the firebox tubes or around the burners, then, once a first layer has formed, fouling occurs rapidly as the outside of the tubes is not "cooled" sufficiently anymore. As the temperatures begin to increase, ashes with higher melting points also start to melt. Thus more deposits are formed and higher temperatures obtained. In addition, a shifting of temperatures towards the super-heaters can be noticed. During operation of the boiler, the ash is sticky and in molten form. It cannot be removed by soot-blowing. The actual time of built-up of such deposits varies from boiler to boiler and depends largely from the firebox design and temperatures. Starting PentoMag 2550 I dosing on a clean boiler prevents slag formation. In the most unfavourable conditions (burning coal with strongly slagging properties in a firebox with very high heat transfer rate), the slagging process will proceed much more slowly and mildly Advantages of using PentoMag 2550 I are given below Optimisation of combustion in coal fired plants Reduction of deposits in burning chamber thus longer cleaning intervals and reduce adverse effects on heat exchanger Deposits are brittle, so that cleaning is easier and piping remains undamaged Higher efficiency due to better heat transfer Higher boiler availability Reduces black smoke and particulate emission through flue gas Efficiency improvement (Reduces exit gas temperature) 5

6 4.0 System Details and Recommended Dosage System Details: Equipment Smoke Tube Boiler Fuel Coal Make VPR Steam Generation Capacity, in TPH 5 Working Pressure, in Kg / cm Running Hours 24 Coal Consumption per month, in MT 750 Coal Size 6-30mm (90%), 25-50mm (5-10%) GCV of Coal, in Kcal / Kg 5000 (average) Landed Price of Coal per MT Rs Cost of Coal per month Rs Recommended Dosage: 100 ppm i.e, 1 Kg of PentoMag 2550 I in 10 MT of Coal. Dosage may vary depending upon nature of fuel and severity of problems. 6

7 5.0 TRIAL METHODOLOGY The performance of Boiler in terms of Steam produced and Coal consumed per day from 25 th Dec 2012 to 4 th Jan 2013 (excluding 5 th Jan because steam production on and above 110 MT are considered in case of both pre and post additive period ) before dosing the additive and from 8 th Jan 2013 (6 th & 7 th Jan readings are not considered because of system stabilization) to 22 nd Jan 2013 (excluding 16 th, 17 th Jan because steam production on and above 110 MT are considered in case of both pre and post additive period and on 13 th & 14 th Jan boiler was not under operation) after dosing the additive were noted. Other operating parameters were noted for understanding the overall Boiler performance during Pre and Post additive period. Dosing of additive has been started from 6 th Jan 2013 morning (around 11 AM) on 100 ppm i.e, 1Kg of additive in 10 MT of Coal. The Steam to Fuel Ratio (Total Steam produced in Kg divided by total Coal consumed in Kg) for pre additive and post additive period are calculated. The percentage improvement in SFR during post additive period over that of pre additive period is taken as the fuel savings. 7

8 Note: 6.0 CONCLUSIONS 1. By using PENTOMAG ppm dosage, fuel savings of 7.36% (Please refer Annexure 1& 2) is realized in your Coal consumption. 2. As a result of this fuel savings, a net minimum monetary benefit of over Rs Lacs per annum (Please refer Annexure 3) can be obtained, after accounting for the cost of additive, through regular usage of additive. 3. Intensity of dark black smoke emission has been reduced drastically and maximum time smoke becomes invisible. Please refer annexure From the first day of post additive analysis, clinker formation is totally stopped. Please refer annexure Quantity of both bottom ash and fly ash get reduced and also there is a change in colour of ash indicating improvement in combustion. 6. Ash disposal becomes easy that leads to higher boiler availability a. It is to be noted that dates in which steam production was below 110 MT are not considered. 5 th, 16 th and 17 th Jan readings are not taken into account because of above mentioned reason. b. For keeping same post and pre additive period, post additive readings up to 22 nd Jan are taken into account otherwise coal savings% will be more. In view of the excellent results achieved by using our additive, we request management of Naachiar Paper Boards for continuous usage of our additive in your Coal fired Boiler; realize the cost benefits and other indirect benefits. Please feel free to get in touch with us for cost effective solutions related to Fuel Management. Thanking you and assuring the best of our attention and services at all times. Yours truly, For TELLABS Chemicals Pvt. Ltd. Bibek Ranjan Guha Sales Manager 8

9 ANNEXURE 1 PRE ADDITIVE READINGS Date Steam Production (Kg) Coal Consumption (Kg) SFR (Kg/ Kg) Remarks 25-Dec Dec Dec Dec Dec Dec Dec Jan Jan Jan Jan Jan-13 Steam production <110 MT Total

10 ANNEXURE 2 POST ADDITIVE READINGS Date Steam Production (Kg) Coal Consumption (Kg) SFR (Kg/ Kg) Remarks 8-Jan Jan Jan Jan Jan Jan Jan Jan Jan Jan Jan Jan Jan Jan Jan Boiler was not under operation Boiler was not under operation Steam production < 110 MT Steam production < 110 MT Total % Fuel Savings = SFR (Post Additive) SFR (Pre Additive) SFR (Pre Additive) = = 7.36% NB: All the Pre and Post additive readings were noted from boiler log book. 10

11 ANNEXURE 3 COST BENEFIT ANALYSIS OF USING PENTOMAG 2550 I Consumption of Coal in boiler, per month in MT 750 Saving achieved by using our additive in % 7.36 Therefore, Anticipated saving in Coal consumption in MT (750X7.36)/ 100 = 55.2 Gross savings per Rs 4000 /Ton of Coal Treatment Cost Calculation: Landed cost of additive, Rs. per Kg (after CENTVAT benefit) Recommended ppm 100 Coal, additive required in Kg per 100 ppm dosage 75 Therefore estimated cost of Additive per month in Rs. 75X = Net savings per month in Rs = Anticipated Net Savings per annum in Rs : 11

12 ANNEXURE 4 PRE ADDITIVE STACK EMISSION POST ADDITIVE SMOKE LESS STACK PRE ADDITIVE CLINKER POST ADDITIVE FRIABLE & EASY TO REMOVE DEPOSITS 12

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