Micro Project: Title of The Project
Micro Project: Title of The Project
MICRO PROJECT
Academic year: 2020-21
1
Government Polytechnic, Nanded
MAHARASHTRA STATE
BOARD OF TECHNICAL EDUCATION
Certificate
This is to certify that members of group 1683, 1663, 1666, 1676,1671 of 5th
Semester of Diploma in Mechanical Engineering of Institute, GOVERNMENT
POLYTECHNIC NANDED has completed the Micro Project satisfactorily in
Subject- PPE(22566) for the academic year 2020-21 as prescribed in the
curriculum.
Place: Nanded
Date:
2
Government Polytechnic, Nanded
Government Polytechnic, Nanded
Mechanical Engineering Department
Academic Year (2020-21)
___________________________________________________________________________
We known the how the maintenance procedure of FBC boiler is carried out.
For making this project we take every group member suggestion and their opinion.
3
Government Polytechnic, Nanded
Government Polytechnic, Nanded
Mechanical Engineering Department
Academic Year (2020-21)
___________________________________________________________________________
We known the how the maintenance procedure of FBC boiler is carried out.
For making this project we take every group member suggestion and their opinion.
4
Government Polytechnic, Nanded
Government Polytechnic, Nanded
Mechanical Engineering Department
Academic Year (2020-21)
___________________________________________________________________________
We known the how the maintenance procedure of FBC boiler is carried out.
For making this project we take every group member suggestion and their opinion.
5
Government Polytechnic, Nanded
Government Polytechnic, Nanded
Mechanical Engineering Department
Academic Year (2020-21)
___________________________________________________________________________
We known the how the maintenance procedure of FBC boiler is carried out.
For making this project we take every group member suggestion and their opinion.
6
Government Polytechnic, Nanded
Government Polytechnic, Nanded
Mechanical Engineering Department
Academic Year (2020-21)
___________________________________________________________________________
We known the how the maintenance procedure of FBC boiler is carried out.
For making this project we take every group member suggestion and their opinion.
7
Government Polytechnic, Nanded
Government Polytechnic, Nanded
Mechanical Engineering Department
Academic Year (2020-21)
PART A
Micro Project Report
___________________________________________________________________________
1.Brief Introduction :- Coal fired boiler system generates approximately 38% of the electric
power worldwide and will continue to be major contributors in the future. New pulverized coal
fired systems routinely installed today generate power at net thermal cycle efficiency ranging
from 34% to 37% (higher heating value) while removing up to 97% of the combined,
uncontrolled air pollution emissions. A new generation of pulverized coal fired boiler technology
is currently under development which will permit generating efficiencies in excess of 42%. This
paper highlights some of today’s design improvements which target reduced emissions and
expanded operability, and explores some of the boiler design implications for the ultra-
supercritical conditions needed to achieve the high cycle efficiencies for the future.
Action plan
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Government Polytechnic, Nanded
topic from internet Shelke Ganesh
3. Collect information about selected topic Panchal Balanand ,
from various reference books Patil Chaitanya and
Prashant Kadam
5. Make project report Sonone Omkar and
Shelke Ganesh
4. Resources Required
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Government Polytechnic, Nanded
Government Polytechnic, Nanded
Mechanical Engineering Department
Academic Year (2020-21)
PART B
Micro Project Report
___________________________________________________________________________
1.Brief Description
1.1 Definition
It is a closed vessel in which steam is produced from water by combustion of fuel. Boiler is an
apparatus in which thermal energy released by combustion of fuel is transferred into water which
vaporizes and gets converted into steam at the desired pressure and temperature.
1.2 Boiler Mounting
Mountings are the components used for the safety of boiler, the boiler requires the following
mountings a feed check valve to prevent the return of water from the boiler in base the feed
pump is to operating, a steam stop valve to regulate the flow of steam from the boiler, safety
valve (at least two) to protect the boiler from pressures higher than the designed valve, a blow off
valve to empty the boiler when needed and to discharge the mud and sediments that are in the
boiler. Water level indicator to show the water level inside the boiler, a pressure gauge to
indicate the pressure of steam in the boiler, fusible plugs to protect the boiler against low water
lever.
1.3 Boiler Accessories
Accessories are the auxiliary plants required for steam boilers for their proper operation and for
the increase of their efficiency. According to the principle of operation the steam separator is
classified as follows:
o Impact or baffle type
o Reverse current type
o Centrifugal type
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Government Polytechnic, Nanded
Boiler efficiency= ma (h-hf)/c
Where, ma = mass of water actually evaporated into steam per kg of fuel at the working pressure
C = calorific value of the fuel in kj/kg.
1.5 Heat Losses In A Boiler Plant
The following heat loss occurs in a boiler plant:
Heat loss of flue gagase
Heat loss due to incomplete combustion
Heat loss due to un burnt fuel
Convection and radial losses
II. MECHANISM OF FLUIDIZED BED COMBUSTION
When an evenly distributed air or gas is passed upward through a finely divided bed of solid
particles such as sand supported on fine mesh, the particles are undisturbed at low velocity. As
air velocity is gradually increased, a stage is reached when the individual particles are suspended
in the air steam- the bed is called “fluidized”. With further increase in air velocity, there is
bubble formation, vigorous turbulence, rapid mixing and formation, of dense defined bed
surface. The bed of solid particles exhibits the properties of a boiling liquid and assumes the
appearance of a fluid- “bubbling fluidized bed”.At higher velocities, bubbles disappear, and
particle is blown out of the bed. Therefore, some amounts of particles have to be re circulated to
maintain a stable system- “circulating fluidized bed”. Fluidization depends largely on the particle
size and the air velocity. The mean solids velocity increases at a slower rate than does the gas
velocity. The difference between the mean solid velocity and mean gas velocity is called as slip
velocity. Maximum slip velocity between the solids and the gas is desirable for good heat
transfer and intimate contact. If sand particles in a fluidized state is heated to the ignition
temperature of coal, and coal is injected continuously into the bed, the coal will burn rapidly and
bed attains a uniform temperature. The fluidized bed combustion (FBC) takes place at about 840
to 950 degree Celsius. Since this temperature is much below the ash fusion temperature, melting
of ash and associated problems are avoided. The gas velocity is maintained between minimum
fluidization velocity and particle entrainment in the gas stream.FBC boilers
combustion progress requires the three “T”s that is time, temperature and turbulence. In FBC,
turbulence is promoted by fluidization. Improved mixing generates evenly distributed heat at
lower temperature. Residence time is many times greater than conventional grate firing. Thus an
FBC system releases heat more efficiently at lower temperatures.
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Government Polytechnic, Nanded
2.2 General Arrangement of AFBC Boiler
AFBC boiler comprises of following systems:
Fuel feeding system
Air distributor
Bed & in-bed heat transfer surface
Ash handling system
2.3 Advantages of Fbc Boilers
o High Efficiency: FBC boilers can burn fuel with a combustion efficiency of over 95%
irrespective of ash content. FBC boiler can operate with overall efficiency of 84% (plus
or minus 2%)
o Reduction in Boiler Size: High heat transfer rate over a small heat transfer area immersed
in bed results in overall size reduction of the boiler.
o Ability to Burn Low Grade Fuel: FBC boiler would give the rated output with inferior
quality fuel. The boilers can fire coals with ash content as high as 62% and having
calorific value as low as 2,500 kcal/kg.
o Pollution Control: SO2 formation can be greatly minimized by addition of limestone or
dolomite for high sulphur coals. 3% limestone is required for every 1% sulphur in the
coal feed.
o Low Corrosion and Erosion: The corrosion and erosion effects are less due to lower
combustion temperature, softness of ash and low particle velocity (of the order 1m/sec)
o Less Excess Air: Higher CO2 in Flue Gas: The CO2 in the flue gases will be of the order
of 14-15% at full load. Hence the FBC boiler can operate at low excess air only 20-25%.
o Simple Operation, Quick Start-Up: High turbulence of the bed facilitates quick start-up
and shut down. Full automation of start up and operation using reliable equipment is
possible.
o Provision Of Automatic Coal And Ash Handling System: Automatic system for coal and
ash handling can be incorporated making the plant easy to operate comparable to oil or
gas fired installation
o High Reliability: The absence of moving parts in the combustion zone results in a
high degree of reliability and low maintenance cost.
o Reduced Maintenance: Routine overhauls are infrequent and high efficiency is
maintained for long periods.
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Government Polytechnic, Nanded
In coal handling plant, raw coal that is brought from outside & bamboo dust is supplied to
griggly hoper whereby help of vibratory machine it is crushed into smaller parts. Then some
amount of bamboo dust is also mixed with charcoal and supplied to primary screen I & II with
the conveyor belt I & IA. In primary screen I&II coal size is checked (i.e. round 6-10 mm). If the
required size is obtained then it goes bunker of CF boiler. If size condition is not satisfied then
the coal goes to crusher I & II. When size is maintained if the coal size is not obtained to the
required size, then it goes to the secondary stages of coal sizing. The acceptable coal size is send
to the boiler through the help of conveyor belt IV.
3.2 Demineralization of Water
It means water is free from all minerals. This is done to various defects happens such as boiler
corrosion, formation of sludge and scale which may decrease the volume or capacity of the boiler
due to deposition of minerals on the walls of the boiler. It is to remove mineral content of water,
in this system raw water enters the hydrogen zeolite exchanger (cation removal) at the top and
flows to the anion exchanger and degasified and finally passes through silicon absorber.
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Government Polytechnic, Nanded
o Keeping the individual damper of 3 compartments in open position, furnace draft is to be
maintained at 5 mm to 7 mm by slightly opening the ID fan damper
o Open the furnace man hole and with 2 mazodoors the bed materials is to be charged into
the furnace, care to be taken that no empty bag slips into the furnace. After completely
charging the material it should be leveled by properly operating dampers of ID & FD
fans, then close dampers. Open the main holes on both sides of the furnace.
o Take a 24v hand lamp inside and measure the height of the bed in each compartment. The
height of bed in each compartment should be 300 mm to 310 mm. Then come out of the
furnace and keep the hand lamp on the bed coils(glowing)
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Government Polytechnic, Nanded
o Open the startup vent valve slightly
o Close all the compartment damper
o Start the ID fan, FD fan, PA fan
o Open slightly the wind box damper of no 1 so bed I fluidizes with minimum air ensure
that fluidization is uniform and satisfactory
o Adjust the ID fan damper to maintain the furnace pressure
o Adjust the FD fan & PA damper to get the required fan pressure
o Start coal feeding without delay otherwise bed may cool down rapidly
o Gradually increase the coal feeding observing the rise in bed temperature
o Adjust the air flow and coal feeding observing the rise in bed temperature
o Take bed no 2 and other beds on line and connect the boiler process
o Take feed water control and furnace draft on auto mode
o Charge the ESP if the flue gases temperature is ok
o Put the boiler into auto mode
o Start ID fan, FD, fan PA fan
o If the bed level is too high drain the bed and bring down the bed height to around 300
mm by fluidizing the bed-1, spread some charcoal over the bed no-1, ignite the same
o Repeat the cold startup procedures listed in this manual and established the boiler.
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Government Polytechnic, Nanded
o Check vibration in rotary equipment
o Check for air/gas leakage from dust & flue
o Check for hot spots bulging etc. on casting dusts etc
o Check the position of damper & cleanliness
o Check the bearing for lubrication & cooling water system
o Check all alarm annunciations with respect to set position
o Check for water, oil along with instrument air
o Check for any unusual smoke conditions
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Government Polytechnic, Nanded
3. Course Outcomes
We known the how the maintenance procedure of FBC boiler is carried out.
4. Procedure Followed
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Government Polytechnic, Nanded