International Journal of Mechanical Science and Civil Engineering

Volume 2 Issue 2 (June 2013 Issue)

Design Aspects of Cow Dung Fired Power Boiler

1 2 3
Gurpreet Singh , Adarsh Kumar , Satbir Singh Sehgal
1
Rearch Scholar, Institute of Engineering & Technology, Bhaddal (Punjab) India
2
Assistant Professor, Institute of Engineering & Technology, Bhaddal (Punjab) India
3
Professor, Chandigarh University, Mohali (Punjab) India
1
grooprai@rediffmail.com, 2adarsh411@rediffmail.com, 3satbirsehgal@gmail.com

Abstract: The traditional means of disposal of solids wastes boiler pressure parts, Abrasion of pressure part.
like municipality waste, Rice husk, sawdust etc. have been
open dumping, land filling or dumping in the sea. This TRAIL RUNS OF AN ATMOSPHERIC FLUIDISED BED
Practice has been discouraged due to non availability of COMBUSTION BOILER ON 100 % COW DUNG
land and new environmental legislation. In India, Boiler
technology is gradually emerging as a potential technology Boiler Description: Boiler is Bi- Drum Water Tube Boiler with
for the incineration of solid wastes like washery rejects and
Atmospheric Fluidized bed Combustion technology with Over
middling, rice husk, saw dust and municipality wastes etc.
Now a day’s different method are developed, to burn the bed Feeding.
Biomass fuel in Boiler at present many biomass fuel like Design Specification:-
Rice husk, Bagasse etc are used but instead of this cow
dung, rice straw & Mustard husk are available in huge 1) Boiler Capacity - 12000 Kg/Hr
quantity but they are not fully used in boiler because of 2) Boiler Pressure - 45 Kg/cm2
their fouling character, keeping in view of the existing
3) Super heater Temp – 420 Degree
properties of Biomass in the present work the authors
proposed the design aspects of the boiler who can run on 4) Boiler Type- Bi Drum FBC Boiler
100% cow dung Fuel & other Biomass Fuels. 5) Boiler Installation Date: 2005
6) Boiler operation on Cow Dung - 2010-2013
INTRODUCTION 7) Boiler Actual running Load – 8000 Kg/hr
8) Operating Pressure – 44 Kg/cm2
The state has the capacity to generate about 200 MW of power 9) Operating Temperature of Super heater – 385 – 420 Degree
through these projects. Punjab Energy Development Agency
10) Boiler Continues operation – 25 days after that shut down
(PEDA) has already identified 135 small micro/hydel sites
for 2 days for Cleaning.
having a potential of generating 135 MW of power.
Government of Punjab has drawn out a proposal for setting up 11) Fuel Feeding – Over bed
10 biomass based projects of total 100 MW capacities in areas
where biomass is available in abundance.) According to a Basic Dimension of Boiler parts:-
survey conducted by PEDA along with the Ministry officials to
ascertain the availability of biomass in 37 tehsils of the state, it 1) Steam drums Diameter -1220 mm x 2500mm Lg
was found that an estimated of 342 MW of power can be 2) Water Drum Diameter – 860mm x2500mm Lg
generated from this sector and setting up of these projects
3) Water wall Size (Furnace size) –4300 Lg x2205 (width) x
would help harness at least 100 MW of the available potential.
10000Lg
COW DUNG PROJECTED AS A SOURCE TO 4) In bed Coils - 50.8mmx 6.35mm thk
GENERATE POWER FOR COGENERATION 5) Water wall Tubes – 63.5 x4.06 thk
6) Super heater Tubes – 38.1 x4.06
Great deal of environmental pressure in many parts of the 7) Super heater Arrangement – Pendant Secondary Super
world to ascertain how livestock waste can best be handled. heater.
Increases in demand, lower emission standards, and reduced 8) No of S.H – Primary S.H (Convection) Secondary SH
fuel supplies have fueled the recent effort to find new and (Radiant).
better fuels to power the necessary equipment for society’s 9) Boiler Bank Tubes – 50.8 x4.06 thk
needs. Often, the fuels chosen for researches are renewable
10) Boiler Bank Flue gas design – 3 pass
fuels derived from research at university level are focused on
the effectiveness of using cattle manure biomass as a fuel 11) Economizer -38.1 x 4.06 thk – single Pass
source. The scope of this project includes fuel property 12) Air Pre heater – 60.3 OD x 2.34 thk – Single Pass
analysis, behavior of Ash accumulation on different parts of

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 International Journal of Mechanical Science and Civil Engineering
Volume 2 Issue 2 (June 2013 Issue)

Boiler Operating Parameters: cleaning.

4) Flue gas outlet Temperature to chimney: 140 degree to 180
degree.
1) Super heater Outlet Pressure: 44 to 45 Kg/cm2
2) Boiler Operating Load: 6 To 7 Ton /hr max
3) Boiler operating days: 6 months operation with regular

Fig.1: Schematic image of pressure parts. Problem faced during operation on Cow dung fuel

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 International Journal of Mechanical Science and Civil Engineering
Volume 2 Issue 2 (June 2013 Issue)

 Boiler Operated on Low Load 6 to 7Ton /hr with 44

Kg/cm2 operating Pressure at Super heater outlet &
 420 Degree as final super heater Temperature 
 In Fluidized Bed Combustion system it is not easy to
run Cow dung as Sand Particles & Stone settle down
on Bed and because of stone & soil particles bed
become heavy results into Non Fluidizing Condition,
so in order to keep bed fluidizing state it is necessary
to drain the bed at regular intervals. However this is
very difficult to drain bed regularly and Keep the bed
 Temperatures 
  Continues Sand Drain is required in 2 hour. 
 Ash Deposition on Water wall due to which Furnace
outlet Temperature increases 
 When we start the boiler we operate Super Heater at
Fig.2: Graphical representation of super heater temperature
temperature 420°C with 10 Degree attemperation.
profile.
However Due to
choking after 20 days super heater temperature comes
down to 380°to 370 Degree because of lower
temperature they are forced to shut down the boiler as
they are doing Power generation.
 Huge choking between super heater & rear wall nose
tube. Choking is due to Sand/Ash, settled on rear
 water wall Panel. 
 Chocking Found between Super heater coils as Super
 heater coils are placed at a pitch of 105 mm. 
 Huge choking We Found on the Top of Water Drum
due to which the Flue gas path totally chocked &
boiler back fires as due to chocking we are not able to
 maintain negative draft in Furnace. 
  We Found lesser chocking in case of Economizer 
 After 20 days operation we found approx 40 % of
total tubes of air pre-heater chocked.  Fig.3: Deposition of ash in super heater after working in 20
 days & due to which high Scaling and fouling takes place
 During rainy season, it is not possible to run boiler
inside the super heater.
with 100% cow dung, so we run with 20% coal as
moisture % increases during rainy season and bed
 temperature lower down 
 Operation without soot blowers is not possible in case
of Cow dung 

Fig.4: Condition of Water Wall after regular operation of 20 days.

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 International Journal of Mechanical Science and Civil Engineering
Volume 2 Issue 2 (June 2013 Issue)

DESIGN OF NEW BOILER RUNNING ON COW DUNG  Rear water wall designed with openings & a hopper is
BASED ON STUDY/ OBERVATIONS & PROBLEMS attached with rear water wall so that during Soot
FACED DURING RUNNING. Blower operation all ash deposited on S.H Coils can
easily be drained through these hoppers or the Ash
Boiler Description:- Settled on Rear waterwall can easily be drained
 through these hoppers 
1) Boiler Capacity - 14000 Kg/Hr  We Proposed Single Drum Boiler to avoid chocking
of Boiler Bank ,we Proposed Evaporater, instead of
2) Boiler Pressure - 45 Kg/cm2 Boiler Bank 
3) Super heater Temp – 460 Degree 
 We Proposed AirPreheater with 76.2 mm Dia instead
4) Fuel Cow Dung – 100% of 60.3 OD earlier used in order to avoid chocking 
5) Boiler Basic Design – Single Drum Water Tube
Reciprocating Grate Boiler When we start the boiler we operate Super Heater with
6) Boiler Installed – 2012 May attemperation of 30degree & maintain Super Heater
temperature at 460°C.However due to choking after 60 days
Boiler operating Parameters – super heater temperature comes down to 460° C without
attemperation.
1) Boiler Type: Single Drum Reciprocating Grate Boiler
2) Boiler Installation Date: 2012
3) Boiler operation on Cow Dung – May 2012
4) Boiler Actual running Load – 12000 Kg/hr
5) Operating Pressure – 44 Kg/cm2
6) Operating Temperature of Super heater – 460ºc
7) Boiler Continues operation – 45 to 60 days after that shut
down for 2 days for cleaning
8) Fuel Feeding – Over bed

DESIGN ASPECTS AND CHANGES IN DESIGN OF

BOILER RUNNING ON COW DUNG AND PROBLEMS
SOLUTION

The authors proposed improved design of Boiler so that Boiler

can easily run on 100 % Cow dung without Break down and Fig. 5: Graphical representation of Improved Super heater
the design changes are as follows:- temperature profile.

 Author Proposed Reciprocating Grate instead of

Fluidized Bed as due to presence of high Sand &
stone articles in Cow dung, Reciprocating Grate is
best option as continues ash discharge is possible in
 this case 
  Super heater Area proposed in 100% convection. 
 Super heater Proposed with Wider pitch of 150 mm
 instead of 105mm of pitch to avoid chocking. 
 Secondary SH designed with Parallel Flow in order to
have lower metal Temperatures and avoid chemical
 corrosion. 
 Two no’s Retractable Soot blower based on cleaning
 radius is also provided in Super heater Zone. 
 Heating Surface of Super heater provided on higher Fig. 6: View of Improved Super heater operating after 60 days
 side with 30 degree Attemperation  of operation.

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 International Journal of Mechanical Science and Civil Engineering
Volume 2 Issue 2 (June 2013 Issue)

4. FUEL ANALYSIS:-

Fuel samples (feed, carryover and overflow) collected from the

1 MW plant at Sainson (Pheowa) and cow dung were
subjected to laboratory for their fuel analysis and analysis
report are as follows:-

Sample Description: Cow Dung

Sample Qty: 1 KG

Table 1. Ultimate analysis:

CONCLUSION

From the analysis it was seen that the new improved design of
cow dung fired power boiler has more efficiency and
effectiveness. The duration of Continues Boiler Operation is
increased thus leading to better cost utilization.

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[4] S.G Fuel analysis Report

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 International Journal of Mechanical Science and Civil Engineering
Volume 2 Issue 2 (June 2013 Issue)

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