INDUSTRIAL TRAINING

AT
NATIONAL FERTILIZER LIMITED
BATHINDA

SUBMITTED BY :-
NAME-AMRITPAL SINGH(1411359)
GAGANDEEP(1411392)
KHUSHDEEP SINGH(1508460)
MOHIT(1508465)
 PLANTS OF NFL
The whole Fertilizer plant is divided into
five plants:
Ammonia Plant
Urea Plant
Steam Generation
 Captive Power Plant
Bagging Plant
 PRODUCTS OF NFL

Kisan urea

Neem coated urea

 STEAM GENERATION
PLANT(S.G.P)

Steam generation plant produces and supplies

steam at 100kg/cm2 pressure and 4800C
temperature to ammonia plant.
For running prime mover
To exchange heat in the processes
 MAIN EQUIPMENT
WATER TUBE Boiler
Economizer
Super-heater
Air Preheater
Electrostatic Precipitors
Bowl Mill
 CAPTIVE POWER
PLANT
Bathinda Unit was drawing power from PSEB.
Electricity is main driving force after steam ,being used for
moving auxiliary equipment.
The unit requires about 27MW of power per hour when
running at full load.
There are two 15MW turbo generators to generate power.

NEED FOR CPP:

Any disturbance in PSEB grid lead in tripping of whole
plant. Moreover frequent tripping had an ill effect on
machines and equipments.
 AMMONIA PLANT
PROCESSES
1. PRIMARY REFORMING
2. SECONDARY REFORMING
3. PARTIAL OXIDATION OF CO
4. CO2 SEPARATION IN ABSORBER
5. SYNTHESIS GAS TO REACTOR
6. CHILLING PROCESS
 UREA PLANT

SYNTHESIS SECTION
DECOMPOSITION SECTION
CRYSTALLIZATION AND PRILLING
 PROJECT UNDERTAKEN
TO ANALYSE THE PROBLEMS OF BOWL
MILL
INTRODUCTION

Bowl Mills are used for grinding the coal. Coal received
from material handling plant is stored in coal bunker and is
fed to the bowl mill through a coal feeder. Coal is used as
fuel. Coal comes from coal handling plant through
conveyor belt.

In Bowl Mill coal is grinded and converted into powder

form. This powder form of coal is sent into the boiler
corners through a pump.
 COAL FIRING SYSTEM

There are two most common methods for feeding coal inside
Boiler:

Stoker Firing:In this system Coal is fed into the furnace for
combustion in lumps form.

Pulverized Fuel Firing: In this mechanism Coal is reduced to

fine powder with help of grinding Mill ands then projected into
Combustion Chamber with help of hot air current.
 TYPES OF MILL
Generally two types of mill are popular in Steam generation
plants:
Ball Tube Mill: The BTM is a steel barrel lined with cast
alloy steel liners and is partially filled with cast &hardened
steel balls. Coal enters the BTM from one end and as BTM
rotates the balls & passes out coal in powder form from the
other end.
Bowl Mill: This is a medium speed vertical mill with conical
grinding rolls 3nos. per mill. The race will be either deep or
shallow like saucer covered with liner called bullring segment.
The bowl is rotated by a gearbox have reducing gear like worm
gear set or bevel helical gears
 PERFORMANCE OF MILL

Performance of Mill depends on following factors:

Grind ability of Coal

Fines of Grind needed

Surface moisture of Coal

 NOMENCLATURE AND THE RANGE OF
BOWL MILL
NOMENCLATURE
• 603 XRS/583 XRS/803 XRP
Bowl mill.
• 60,58,80 stands for bowl
diameter in inches.
• 3- Number of Rollers
• X- Frequency of Power
supply(50 Cycles)
• R- Raymond, name of the
inventor
• S- Suction type with
Exhauster after mill
• P- Pressurized type with
P.A. Fan before mill
RANGE
• BHEL manufactures Bowl
mills in the following ranges
(corresponding to Bowl
diameter in inches)
• 1. 60” series: 583, 603&
623 XRS/XRP
• 2. 66” series: 663 XRP
• 3. 70” series: 703 XRP
• 4. 80” series: 763, 783, 803
XRP
• 5. 90” series: 883 XRP
 OPERATING PRINCIPLE
The Coal from RC Feeder is fed into center of rotating
bowl of Mill. The Coal comes in between the grind roll
and bull ring segment and get crushed in between by
spring force on grind roll. The fine grain is dried and
carried by primary air to the boiler through coal nozzle.
Mill is equipped with the stationary classifier with
adjustable vanes for adjustment of coal fineness. The
coarser particles in the pulverized coal are separated in
the classifier and returned back to the bowl for further
grinding.
 OPERATING CONDITION OF
BOWL MILL
Mill outlet temperature should be between 70-
85 deg. Cent.
Exhaust pressure : 300mm of water column
Proper classifier vanes adjustment
Proper clearance between grind rolls and bull
ring segment should be 3mm.
Proper clearance between spring and grind roll
assembly should be 1mm.
 INSPECTION TO ENSURE OPTIMUM
PERFORMANCE:
♦ Fan Blades
 Inspect the condition of each fan blade and the bolts securing
blades to the exhauster.
 Lengths and breadth should be measured. Ensure that all fan
blades are of similar lengths (±1/8"). Clearance between the fan
blades and the back plate should be 9/16” ±3/16” (3/8” to 3/4”).
♦ Whizzer Blades
Inspect the condition of and clearance of whizzer blades. Worn
blades must be pad welded or replaced.
♦ Fan Spider
• Inspect the fan spider for erosion. Any erosion must be repaired to
prevent catastrophic failure of Exhauster. In most cases, moderate
erosion may be repaired by pad welding.
• Symmetrical, exhauster must be balanced after repair. Dye-
Penetrant or “Mag-Particle” checks for cracking of the spider is
recommended.
♦ Ceramics and Periphery Liners
Inspect the ceramic and internal liners for erosion and
integrity. Any worn liners or missing ceramics must be
replaced.
Inlet and Outlet Piping
Inlet and outlet piping should be inspected for areas of
excessive erosion or holes.
Spring Compression
is mandatory for satisfactory pulverizer fineness and
capacity. During operation, spring compression can be
checked by observing spring deflection. Spring deflection
should be 22 mm to 25mm at full pulverizer loading and
should be uniform between journals.
Classifier Setting After Pulverizer Overhaul

All Classifier blades for each pulverizer will be set to position

after a pulverizer overhaul. After start-up, coal fineness
testing will be conducted at full pulverizer load to determine
coal fineness.
 MAINTENANCE OF BOWL
MILL
Preventive Maintenance having following parts
1. We change following parts after certain working hours.
Grind roll :800 hours
Bull ring segment: 2000hours
Vertical shaft: 1.5 –2 yrs.
Top liner: 1200 to 1500 hrs.
Blade: 2000 hrs.
2. Following inspection is done as per schedule
Oil circulation
Scraper check
Grind roll oil check
Worm shaft play check
Mill bolt tightening
 PROBLEMS IN BOWL
MILL
The major problem in bowl mill is continues stopping of
bowl mill. The main reasons for that are following
High density impurity (stone) in coal
Over feeding
Low spring tension
High clearance between bull ring segment and grind roll
Low air flow
Low air outlet temperature
Worn out parts of roller or bull ring segment
Jamming of roller
Restriction of air flow
Less Exhauster Pressure
closing of exhauster inlet valve
Chocking of P.F. Pipe
Chocking of classifier vanes
Leakage in suction pipe of mill/ Exhauster
Vertical shaft failure
Abnormal noise in mill base
Abnormal noise in mill side
Abnormal noise in separator body
High mill base oil temperature
High pulverized fuel fineness
low pulverized fuel fineness
 MILL FIRE
Mill catches fire due to following reasons
Excessive mill temperature.
Foreign materials such as paper, woods etc.
collects in inner cone or other point of the mill.
 REASON FOR VERTICAL
SHAFT FAILURE

 Impure shaft material

Uneven loading of Grind roll
Uneven wear of grind rolls/ bull ring segment.
Uneven gap between bull ring segment and
grind roll.
Uneven gap between spring and grind roll.
 EFFECTIVE SOLUTIONS

For high rejection-

Foreign material, over feeding, low air flow, chocking
should be avoided.
Proper clearances should be provided b/w grind roll&
bull ring segment, spring & grind roll.

For Vertical Shaft Failure-

There should be equal gap b/w rollers & bullring
segment.
Spring loading should be same for all three rollers.
THANK YOU