TATA BF G, PCI

General Operator Training May 2005

Mr. Jim Plooij Process Technologist

2. Course general overview

> > > > > > > > > PCI System and equipment description Control systems Feed tank cycle Injection line purging / cooling Injection start Injection and feed tank stops Feed tank control Feed tank cycle sequence Coal return

3. PCI system overview

PCB-300

4. Screens
COAL FROM PCB-300

VENT LINE TO PCB-300

PCB-300

5. Feed tank

> FT-410, FT-420

> > > > Volume: Filled coal weight: Empty coal weight: Operating pressure: 43.5 m3 18 ton 3 - 5 ton 4 9.1 bar

6. Mixing tee

> MT-440
> > Operating pressure: Design temperature: 3 8 bar 60 85 oC

7. Distributor

> D-500
> >
> Square pipe to ensure homogenous coal nitrogen flow enters distributor and even distribution to each transport line

Operating pressure: Design temperature:

2 5 bar 85 oC

8. Injection lines to tuyeres

INJECTION LINES

9. Injection lance

10. Equipment codes

> > > > > > PCB SC FT MT D BF Pulverized Coal Bin Screen Feed Tank Mixing Tee Distributor Blast Furnace

11. Valve numbering

3 PCB 4 FT, MT 5 DIST, BF

> PCV4113
FT410

> PCV4223
FT420

> Second number is the FT number

12. Control systems 1. PCI rate 2. Fluidization rate 3. Transport nitrogen rate

13. PCI rate control

CASCADE, Weight > Weight controller
> Controls tank weight loss with P (FT - BF)

> Pressure controller

> Control P (FT - BF) with PCV-4113 %, and PBV-4121 O/C

Slow control action

Fast control action FT Pressure drop control PdIC4101

PCI SP t/h

FT Weight loss control WIC4101

P SP bar

PCV4113 % PBV4121 O/C

Measured PCI rate t/h

Measured P bar

FT Weight cells

FT pressure Blast pressure

14. Fluidization control

> FT fluidisation is controlled for the Actual volumetric flowrate, Am3/ h.

m3/h

m3/h

15. Fluidization control

> The coal must be continuously fluidized to ensure smooth flow during injection. > If fluidization is too low the coal flow from the FT will be unstable. > If the fluidization rate is too high injection rate control at low injection rates will become unstable. > Set point during pressurizing > To clean fluidization plate MAX 100% open

16. Fluidization set point

> At low injection rates the fluidization can be decreased. This helps lower the coal flow.

20 18 16 14 12 10 8 6 4 2 0 10 15 20 25 30 35 PCI rate SP, t/h 40 45 50

Fluidization rate SP, Am3/h

17. Transport nitrogen control

> Transport nitrogen flow rate is controlled in Nm3/ h with FCV-4411.
H, M, L , VL tph
o

set point

Nm3/h

C Nm3/h

bar m3/h

18. Transport gas rate set point

3000 Tranpost N2 rate SP, Nm3/h 2800 2600 2400 2200 2000 1800 1600 1400 1200 1000 10 15 20 25 30 35 40 45 50 PCI rate SP, t/h

19. Transport gas rate

> Lower rates may be used after system trials and approval by DC > At low injection rates a higher transport gas rate is required to maintain the pressure difference between the distributor and the BF > In general higher rates lead to a more stable injection behavior.
> Thus during operation if unstable injection is observed by the operators (violent fluctuations in MT pressure PT-4411 and coal rate) a higher transport gas rate should be used. > Unstable injection may occur to factors such as coals with a bad handleability and unstable BF operation.

20. Fluffing
> Fluffing is required to keep the coal fluidized in the ultra-high dense line to the mixing-tee during feeding > When FT is not feeding extra fluffing is used to ensure smooth flow during feeding > Fluffing must not be changed by operator during normal operation > If feed line blocks it can be blown clean by opening the manual fluffing valves

*
PBV4171

PBV4161

When PBV4171 closes PBV4161 opens

21. FT batch cycle

Feeding De-pressurizing Preparation Filling Slow-pressurizing Quick-pressurizing Holding

>

Injecting coal into the furnace

>

De-pressurizing empty FT from injection pressure to atmospheric pressure to allow filling Filling of FT with coal from the PCB-300 via the sieves

>

>

Slow-pressurizing with fluidizations and fluffing nitrogen Quick-pressurizing FT to injection pressures of feeding tank with PCB-4113 and PBV4114 Holding (waiting) period waiting until feeding FT is empty to start feeding, follows feeding FT pressure set point

>

>

22. FT batch cycle times

> > Max. design PCI rate: Feeding / preparation time:
> > > > De-press: Press: Filling: Holding: 4 min 6 min 7 min 0.8 min

43.6 tph 17.8 min

Feeding De-pressurizing Filling

Slow-pressurizing Quick-pressurizing Holding

>

Total cycle time (2FT):

35.6 min

FT-410 FT-420
0 5 10 15 20 25 30 35 40 45

>

No slow pressurization at maximum design rate due to short feeding / preparation time

23. FT Cycle times at low PCI rate

> > > Nominal PCI rate: Feeding / preparation time: Total cycle time (2FT): 20 tph 39 min 78 min
Feeding De-pressurizing Filling Slow-pressurizing Quick-pressurizing Holding

FT-410 FT-420
0 5 10 15 20 25 30 35 40 45 50 60 70 75

Quick-press. + holding = 10 min (constant for all PCI rates)

> > >

Slow-pressurizing occurs between filling and quick pressurization if the cycle time is long enough The total quick-pressurization time + holding time is then set to 10 minutes Slow-pressurization is used instead of a longer hold time to save nitrogen and reduce wear of system valves

24. Feed tank cycle graph

WIC4101 output %
PdIC4101 WIC controlling t/h to t/h SP

Holding
P SP from FT420 Holding

P SP P
Depress.

Quick press. Quick pressurization

Slow press.

Slow Filling t/h SP t/h

pressurization

FT420 feeding

Start Preparation FT410

Start feeding FT410 Start feeding

25. Purging / Cooling injection lines

> Purging - cleaning > Cleaning of build-up in lines and on lance tip (ash) > High velocity per line Cooling emergency / cooling > Purging of all lines simultaneously for cooling only (not cleaning) > Lower velocity than for cleaning > Lances without PCI injection must always be cooled during BF operation to protect the injection lances

>

26. Purging injection lines - system

x 30

x 30

PS5002

CHV5001

27. Purging injection lines

> Automatic cycle > Selected by pressing Start on Distributor screen > 2 minutes per lance all lances from 1 to 30 > Interval between cycles chosen by operator (2.5 to 8 hour), nominal time = 8 hours > Manual > Operator selects lance and duration on lance pop up on Distributor screen

28. Purging injection lines, Screen

29. DC recommendations
> A maximum of 3 lines to be purged during BF operation with PCI Purging of 2 or more lances next to each other during BF operation with PCI must also be avoided at all costs Not abiding by these rules for long periods can lead to unsymmetrical burden decent and an unstable BF process due to, > Significantly higher coke consumption above purging tuyeres > Significantly higher heat input above purging tuyeres

>

>

30. Injection start

> Initiated by operator by pressing INJECTION ON button on injection overview > Used by operator to start injection after both feed tanks have been set In cycle by operator and one is in holding > Sequence,
> Check start conditions > Check operational conditions > Distributor coal valves PBV5011 5301 > Nitrogen purge valves PBV5012 5302
> Holding FT set in feeding phase

OK OK open close

> Injection ready displayed on injection overview screen

> If both FTs are holding the FT with the least coal starts

31. Start conditions (SC)

32. Injection start controls

33. Injection and Feed tank stops

> Normal Injection stop (NS)
> To stop injection. Operator or automatically initiated

>

Emergency stop (ES)

> Automatically activated when one of the emergency conditions is not met. Full injection stop. Not operator initiated

>

FT out cycle
> To stop one FT at the end of its current cycle, after depressurization

>

FT fast stop
> To stop one FT due to an emergency situation with that specific tank

34. Normal injection stop (NS)

> Initiated by operator by pressing INJECTION OFF button on injection overview
> > > > The feeding FT goes into holding The preparing continues to holding Transport nitrogen blows lines clean for 2 minutes All injection lines are set to purge

> After a Normal Stop both feed tanks will remain in cycle, and in the holding phase. > When injection starts the FT with the least coal will start injection.

35. NS automatic interlocks

36. NS Controls

37. NS comments
> > After a normal stop both feed tanks remain in holding If the injection stop is for an extended period > 30 min one or both of the feed tanks should be stopped, depressurized (Fast Stop) This is to protect the venting valves fro excessive wear, and reduce nitrogen consumption

>

38. Emergency stop (ES)

> To prevent hot blast entering injection lines
> All injection lines set into purge/ cooling

> > >

Not operator initiated Not in operation with injection off Not in operation for the first 60 seconds of injection

39. ES automatic interlock

40. ES Procedure > All injection lines are isolated and purged/ cooled
> Distributor valves PBV5001 to 5301 > Nitrogen purge valves PBV5012 to 5302 CLOSE OPEN

> The feeding FT goes into holding > The preparing continues to holding > After a Normal Stop both feed tanks will remain in cycle, and in the holding phase > When injection starts the FT with the least coal will start injection

> After an Emergency Stop the transport line remains partially filled with coal. It is automatically blown clean with transport nitrogen for 30 seconds when starting injection

41. FT Controls

42. FT In cycle
> Initiated by operator by pressing In cycle button on FT screen
> Used to start the FT operational cycle

> Starting interlocks

> > > > > > PCB level Nitrogen supply (PIT0801) Fluidization flow Instrument nitrogen pressure Valves Weighing system > 50 tons > 10 bar > 3 Am3/ h > 5 bar OK OK

43. FT Out cycle

> Initiated by operator by pressing Out cycle button on FT screen > Used to stop one FT at the end of its current cycle
> The FT completes its cycle up to and including the depressurization phase > The other feed tank continues its normal cycle

> BEWARE!: if you set a FT to out cycle make sure you put it back in cycle with enough time to prepare for injection before the other FT is empty if injection must continue

44. FT Out cycle

Feeding De-pressurizing Filling Slow-pressurizing Quick-pressurizing Holding

> FT cycle continues to depress and stops.

FT-410 FT-420

45. FT Fast stop

> Initiated by operator by pressing Fast stop button on FT screen > Used to stop one FT due to an emergency situation with that specific tank, such as a leakage
> > > > > > Emergency valve PBV4141 Pressure valve PBV4112 Pressurizing valve PBV4114 Fill valve PBV4131 Feeding valve PBV4171 De-pressurizing valve PBV4122 close close close close close open FT de-pressurized

> The other tank continues feeding or automatically completes its preparation cycle and starts feeding as soon as possible

46. Starting after a FT Fast stop

> To put a FT back in cycle the following steps must be taken by the operator

1. Reset the FT by pressing the RESET button on the FT screen 2. Put PBV4141 into MANUAL 3. Open PBV4141 4. Put PBV4141 into AUTO 5. Press IN CYCLE on the FT screen

47. FT Reset
> > Initiated by operator by pressing Reset on FT screen Used to sets FT valves to safe condition when out of cycle. For example after a Fast stop or after maintenance
Pressure Valve PBV4112 Pressurizing Valve PBV4114 Depressurizing Valve PBV4122 Vent Valve PBV4121 Fill Valve PBV4131 Fill Valve PBV4132 Feed Valve PBV4171 Emergency Valve PBV4141 Fluffing Valve PBV4161 close close open open close close close open open

> > > > > > > > >

48. FT cycle sequence step description

> This is initiated by the operator after pressing the In cycle button on the FT screen. > This sequence is also followed during normal FT cycle operation (except for the start step) > > > > > Start (only during first start-up) Filling Pressurization Feeding Depressurization

49. Start sequence

> > Resets FT MCC for Vibrating Screen SC-410 Check

50. Filling sequence

> > > > > > Fill Valve PBV4132 Vibrating Screen SC-410 Fill Valve PBV4131
> Wait until FT is full, approx. 15 tons

open start open close stop close

Fill Valve PBV4131 Vibrating Screen SC-410

>

After delay of 30 seconds minute to empty screen ( 1.3 ton)

Fill Valve PBV4132

51. Pressurization sequence

> > > > Depressurizing Valve PBV4122
> >

close open close maximum

Slow pressurizing, wait until feeding FT has 10 minutes feeding remaining Wait until SP 0.3 bar

Quick pressurizing, valves PBV4112/PBV4114 Pressurizing valve PBV4114 Fluidizing flow rate
>

When FT has reached the pressure set point the FT enters the holding phase

Quick press. Slow press.

52. Feeding sequence

> > > > > Feed Valve PBV4171 Fluffing Valve PBV4161
> Feeding, wait until FT is at minimum weight

open close close open close

Feed Valve PBV4171 Fluffing Valve PBV4161 Pressure Valve PBV4112

53. Depressurizing sequence

> > > Venting Valve PBV4121
> Wait until FT pressure is 4 bar

open open

Depressurizing valve PBV4122

Note, the depressurizing valve PBV4122 only opens when the FT pressure is under 4 bar. This is to prevent a sharp pressure increase in PCB-300

Slow depress. Fast depress.

54. Coal return

> To remove residual coal from a FT that is not in operation (Out cycle)
> > To allow maintenance To prevent settling of coal during long stops (> 8 hours) with no fluidization
> Note a FT can remain full indefinitely if the fluidization is on

TO PCB

COAL RETURN
BAV-4141

55. FT coal return steps

> > > > > > > > > > Operator presses Coal Return button on the FT screen Emergency valve PBV4141 CLOSE Depressurization valve PBV4122 CLOSE Venting valve PBV4121 In vent control PdIC4101 controller gets its automatic coal return set point (5 bar FT pressure) Pressure valve PBV4112 OPEN
> > The FT is pressurized with PCV4113 Operator waits until FT is empty (coal rate = 0 t/h)

Operator opens coal return valve BAV4141 Operator closes, opens and re-closes BAV4141 a few times to make sure FT is completely empty Operator presses Fast stop on FT screen Operator presses Restart on FT screen

56. Coal return

BEWARE! > Do not stop coal return before the FT is empty. This can lead to a blocked coal return line.