1

th
28 June’07
Steam generation in SA Plant with HFO as fuel

LP Steam generation using SA plant WHB I with HFO as fuel was thought of for running the ALF3 plant.
The following modifications were done in the existing system for generating 3 T of LP steam (4-5
KSCG):
1. WHB I outlet was connected to 1431 old convection box which was installed as an Economizer and
then to stack. Ducting (28”) was taken from WHB I smoke box M/H to economizer bottom.
Accordingly the M/H size was also increased from 22” to 28”. This was done to achieve maximum
thermal efficiency.
2. The estimated air requirement for combustion and further dilution was 8000 -10000 NM3/hr. Since
the existing Main air blower and Booster blower capacities are more than the requirement, spare
Digester exhaust fan of capacity 22000 NM3/hr with VFD for air flow control was installed. The
discharge was connected to “A” damper d/s duct M/H.
3. Bund wall was constructed at the upstream of both D1/D2 dampers to avoid entry of flue gas into
HGF and Converter.
4. DMW pump with 60 M head was used for BFW service and the discharge was hooked up to
economizer inlet and the outlet of the coil to Boiler drum.
5. Steam to Super heater /WHB III lines were slip plated. Also, in the airflow path Slip plate was
provided at the d/s of the A damper to avoid air entry to ADT.
6. A temporary tank (3KL) was installed and LDO from the tank (12 KL) was transferred to the
temporary tank. Line connections were given from the temporary tank to the pump suction with spill
back arrangement.
7. 12 KL tank was utilized for receiving HFO either from DAP or from Ammonia. Tapping was taken in
the HFO main header to the tank. Also, the inbuilt steam heater coil was introduced into the tank.
An additional steam heater (shifted from DAP II) was pro vided for better heating of HFO.
8. Necessary rerouting were done in the lines to FO pump so that one pump could be used for
circulation of HFO through the additional heater to the tank and the other one could deliver oil to
furnace.
9. Necessary instrumentation was done for Temperature/Pressure indications and trip logic for Boiler
drum Low level.

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Plant was started with LDO firing on 11 June ‘07 at 21.55 hrs. In Sulphur furnace LDO was fired using
the original dual gun assembly which is having two gun tips each for LDO and HFO with swirler inside
for oil atomizing. The generated steam was consumed in ALF3 Plant through the let down valve PCV
6051. 5 KL of HFO was received from DAP in 12 KL tank and heating was done with steam.
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All parameters were monitor ed and steam production of approximately 3.5 Tph was achieved. The
steam pressure was maintained around 4 -5 Ksc. The temperatures were found to be:

o
1) Furnace temperature : 650 – 700 C
o
2) WHB I o/l temperature : 200 – 260 C
o
3) Convection box o/l temperature : 150 – 180 C
o
4) BFW temperature : 100 – 130 C
0
5) Steam temperature : 150 – 160 C

The quantity of LDO consumption was found to be around 250 – 260 lit/hr.
0
HFO was lined at 2150 hrs on 12.06.07 when the oil temperature reache d 95-98 C. Initially the oil
pressure was maintained at around 7 -7.5 KSCG. Firing was upset as soon as HFO was drawn from
DAP. This was due to sudden dumping of HFO in the tank and caused the oil temperature reduction to
0
65 C. Due to improper atomizing, flame was not steady and oil dumping was noticed. So, LDO firing
0
was resumed on 13.06.07 at 0900 hrs. Again the HFO temperature was raised to 95 C and firing with
HFO was done on 13.06.07 at 1830 hrs with oil pressure at around 9 -10 Ksc and blower frequency at
24 Hz. Average consumption of HFO during the period was around 350 Lit/hr. But firing was stopped
on 14.06.07 at 1900 hrs due to the following problems:
Problems faced during HFO firing were:
o
1. Oil was found dripping from the gun tip even after raising the temperature to 98 C,
2. Furnace front mantle developed large hot spots. Weld joints at the inner circumference of the outer
mantle at the front was found to have cracked. At the base of the outer mantle end cover , oil was
found dripping. The same phenomenon was experienced in LDO firing also.
3. Gun choke was also a major constraint during HFO firing. Frequent gun choke was observed which
affected continuous production of steam. Every time gun choke was found, it was cleaned and
taken in line. Carbon deposits were found at gun tip due to incomplete combustion. By this time ,
temperature of furnace dropped which made fuel consumption more for frequent start -ups.
4. The receipt of HFO from DAP in LDO tank drastically reduced the temperat ure of circulating HFO.
The inlet of HFO from DAP was at the suction of the fuel oil pump, so a proper time for mixing of
circulating HFO with the receipt was not given. This in turn affected the viscosity and thereby oil
dripping was observed.
o
Temperature of circulating HFO : 95 – 100 C
o
Temperature of HFO received from DAP : 30 – 40 C
The problems were analyzed and the rectification jobs carried out were:
1. On detailed analysis it was found th at the gun tip where atomizing takes place sides by the gun
port was 70 mm behind the primary air port. The gun tip is located 230 mm from the front of the
furnace. The primary air port was located 300 mm from the front of the furnace. This caused the oil
which dripped from the gun tip to enter the primary air port and collect in the mantle. The oil started
burning in the mantle and produced hot spots. So the gun assembly was extended so that the tip
was 300 mm from the furnace front. The outer sleeve was a lso extended accordingly. T he gun tip
hole size was reduced from 5.1 mm to 2.5 mm. In order to prevent oil dripping into the air port, it
was decided to increase the velocity of the primary air. The sulphur guns have 4 primary air ports
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each. In each sulphur gun 2 ports were blocked with bricks and refractory so that the velocity of air
through the other ports increased.
2. B damper operation was once again checked and exact operation details were recorded.
3. HFO receipt line was rerouted to the center of the ta nk along with spill back instead of northern
entry where the pump suction nozzle was taken.
4. Clinker deposits inside the furnace and at the outer mantle were cleaned and a minor pointing work
was done on the castable refractory.
5. The defective weld joints at the furnace front were repaired.

Since the plant was under shutdown from 14.06.07 to 17.06.07 , HFO couldn’t be fired since the
0
temperature of the oil was 65 C only. So, again LDO equivalent oil was used and furnace was fired at
1215 hrs on 17.06.07. On 18.06.07 at 1730 hrs HFO was fired. Firing was stable and complete
combustion was achieved.
Following were the parameters maintained in HFO firing:
Oil Consumption rate 250-260 lit/hr.
0
Furnace temperature 620-650 C
0
WHB outlet flue gas temperature 230-240 C
0
Flue gas temperature at the exit o f Coil 160-170 C
0
DMW temperature at the exit of Coil 90-95 C
Steam generation quantity 2.8-3.2 MT/hr.

Conclusion:
HFO firing has been successful and continuous for more than 7 days without any major upset
and the thermal efficiency achieved was around 80% against the estimated value of 70%. The
total cost per ton of steam produced was around 1560 Rs./=. But the consumption in ALF3 Plant
was around 1.0-1.5 MT/hr. only. With the available gun the minimum possible stea m generation
quantity was 2.8 MT/hr. only.
With lesser sized gun tips, it might be possible to reduce the steam production further to match
consumption.
 SA STEAM HEADER

FROM PHASE I TO VENT

PCV 1115

FROM TO Alf3
ADT
PCV 6051

COMBUSTION
AIR FAN TO SUPER HEATER
PG
SLIP PLATE STEAM TO HEATER

FLUE GAS OUT

A DAMPER TI TI TO
SLIP PLATE DEARATOR

V1107 STEAM
TI PG DRUM 1431
CONVECTION
BOX
TI

FURNACE E1101
BOILER
TI
PG

DMW FROM
WTP

LCV

DMW
TANK

HFO / LDO TO FURNACE

TI
SPILL BACK

LDO FROM
UREA

FOR HFO CIR’N

LDO
TANK

HFO TANK

CONDENSATE O/L

HEATER
HEATER
FUEL OIL PUMP A/B

FROM PHASE I CONDENSATE O/L

TO DAP DAY TANK