1.

Discuss about India Boiler Act Introduction: Accordinng to the Indian boiler act 1923 it is An Act to consolidate and amend the law relating to steam-boilers . True to its tag line the act was introduced to standardize and legalise the procedures related to boilers and accessories. It contains 35 sections each covering various aspects of the act. Sections: Sections 1 and 2 assigns a common name to act and defines various terms related to the act. 2a&b extends the act to economizers and feed pipes. Sections 3&4 states limitations of act on ships and railways and certain govt., usage exclusions. Sections 5 lays out the posts of Chief Inspector, Deputy Chief Inspectors and Inspectors their qualifications and duties. Section 6 prohibits unauthorized boilers and condition for their unauthorisation. Sections 7 and 8 explains registration and renewal of boilers. Sections 9,10,11 states circumstances under which boilers can be operated under provisional orders. Sections 12 and 13 prohibits unauthorized changes to boilers. Sections 14 states duty of owner at inspection date. Sections 15,16,17,18,19 state how Production of Certificates, Transfer of Certificate should be done, Powers of entry of inspector , Report of accidents ,Appeals to Chief Inspector. Sections 20 to 27 talks of the power of inspector Section 27A declares a Central Boilers Board . Sections 28 to 30 tells about the power of the board. Sections 31to 34 talks of relationship of government and board . Section 35 is about the repeal of act.

2. Describe the working principle of pulverized mills. Coal is pulverized (powdered) to increase its surface exposure thus permitting rapid combustion. Efficient use of coal depends greatly on the combustion process employed. For large scale generation of energy the efficient method of burning coal is confined still to pulverized coal combustion. The pulverized coal is obtained by grinding the raw coal in pulverising mills. The various pulverising mills used are as follows: (i) Ball mill (ii) Hammer mill (iii) Ball and race mill (iv) Bowl mill. The essential functions of pulverising mills are as follows: (i) Drying of the coal (ii) Grinding (iii) Separation of particles of the desired size. Proper drying of raw coal which may contain moisture is necessary for effective grinding. The coal pulverising mills reduce coal to powder form by three actions as follows: (i) Impact (ii) Attrition (abrasion) (iii) Crushing.

Most of the mills use all the above mentioned all the three actions in varying degrees. In impact type mills hammers break the coal into smaller pieces whereas in attrition type the coal pieces which rub against each other or metal surfaces to disintegrate. In crushing type mills coal caught between metal rolling surfaces gets broken into pieces. The crushing mills use steel balls in a container. These balls act as crushing elements.

BALL MILL A line diagram of ball mill using two classifiers is shown in Fig. It consists of a slowly rotating drum which is partly filled with steel balls. Raw coal from feeders is supplied to the classifiers from where it moves to the drum by means of a screw conveyor. As the drum rotates the coal gets pulverized due to the combined impact between coal and steel balls. Hot air is introduced into the drum. The powdered coal is picked up by the air and the coal air mixture enters the classifiers, where sharp changes in the direction of the mixture throw out the oversized coal particles. The over-sized particles are returned to the drum. The coal air mixture from the classifier moves to the exhauster fan and then it is supplied to the burners.

BALL AND RACE MILL The fig. shows a ball and race mill. In this mill the coal passes between the rotating elements again and again until it has been pulverized to desired degree of fineness. The coal is crushed between two moving surfaces namely balls and races. The upper stationary race and lower rotating race driven by a worm and gear hold the balls between them. The raw coal supplied falls on the inner side of the races. The moving balls and races catch coal between them to crush it to a powder. The necessary force needed for crushing is applied with the help of springs. The hot air supplied picks up the coal dust as it flows between the balls and races, and then enters the classifier. Where oversized coal particles are returned for further grinding, where as the coal particles of required size are discharged from the top of classifier. In this mill coal is pulverized by a combination of' crushing, impact and attrition between the grinding surfaces. The advantages of this mill are as follows : (i) Lower capital cost (ii) Lower power consumption (iii) Lower space required (iv) Lower weight.

However in this mill there is greater wear as compared to other pulverizes. The use of pulverized coal has now become the standard method of firing in the large boilers. The pulverized coal burns with some advantages that result in economic and flexible operation of steam boilers. Preparation of pulverized fuel with an intermediate bunker is shown in Fig. The fuel moves to the automatic balance and then to the feeder and ball mill through which hot air is blown. It dries the pulverized coal and carries it from the mill to separator.

SHAFT MILL The fig. shows fuel pulverization with a shaft mill. The fuel from bunker is moved to feeder via automatic balance. Then from duct fuel goes to mill where it is crushed by beaters secured on the spindle of the mill rotor. The pulverised fuel is dried up and then blown into shaft by hot air. Secondary air is delivered into the furnace through holes to burn the fuel completely.

3. Explain the cogeneration principle and discuss cogeneration with a case study. Introduction: Co-generation is defined as the sequential generation of two forms of useful energy from a single primary energy source, typical two forms of energies are mechanical energy and thermal energy. Mechanical energy may be used may be used to either to drive an alternator to produce electricity or rotate an equipments like motor, compressor, pump or fans etc., for delivering different services. Thermal energy may be used directly for the process for heating purpose or indirectly to produce the steam generation, hot water or hot air for dryer and chilled water generation for process cooling. Generation of three different forms of energy from the single primary energy source is called as Tri-generation, i.e., generation of Electricity, Steam or Hot water and Chilled water from single source of primary fuel. Above both systems is also called as Total Energy System.

Case Study: Sakthi Sugars Limited The power division operates Co-generation Power plants at Sakthinagar, Sivaganga and Modakurichi. The aggregate power generation capacity of all three plants is 92 MW. These Plants are using waste starch produced from their sugar mill. Sakthinagar Co-Generation 32 MW The plant was established in the year 2003 with a capacity of 32.0 MW Power Generation. Plant Features

The plant is operational with High Pressure Boilers and Turbines (87 Ata 510 Deg.C) and Multi Fuel Boilers with Bagasse , Biomass and Coal.

Sivaganga Co-Generation 35 MW The plant was established in the year 2008 with a capacity of 35.0 MW Power Generation. The plant is operational with Multi Fuel High Pressure single Boiler and single Turbine. Plant Features The plant is operational with High Pressure Boilers and Turbines (108 Ata 540 Deg.C) and Multi Fuel Boilers with Bagasse, Biomass and Coal. Most of the equipments used for power generation are imported from China. Equipped with advanced machineries to ensure energy saving. Equipped with sophisticated instruments and controls so as to operate the entire plant through DCS. Equipped with state of the art ESP and pneumatic ash conveying system to prevent air pollution.

Modakurichi Co-Generation 25 MW The plant was established in the year 2007 with a capacity of 25.0 MW Power Generation. The plant is operational with Multi Fuel High Pressure Boilers and Turbines. Plant Features The plant is operational with High Pressure Boilers and Turbines (108 Ata 540 Deg.C) and Multi Fuel Boilers with Bagasse , Biomass and Coal. Air Cooled Condensers in place of water cooled condensers. Most equipments used by the plant are imported. The power generated by these plants is utilized for their associated sugar and distillery units and the surplus power is exported to the grid.