Bagasse Fired Boiler Duct Explosion

Avant-Garde Engineers and Consultants Private Limited
November 5, 2008
1.0 Note on explosion incident in flue gas ducting during start-up /

commissioning of bagasse fired boiler.
1.1 Avant-Garde has come across the following problems during the
commissioning of bagasse fired boiler in sugar industries, particularly
during the start-up / commissioning period:
Explosion in Electro Static Precipitator (ESP)

Burning of collecting and emitting electrodes inside the ESP
Explosion in flue gas ducting
It has been established that the main reason for the explosion and
burning of elements in ESP was due to carry over of unburnt, not
evacuating the ash / unburnt on a continuous basis from the ash hoppers
and large quantities of smoldering fuel on the grate. The unburnt in the
ash hoppers leads to internal firing and smoldering due to the air leakage
from the RAVs / slide gates / knife gates / flange joints / bolt holes.
One case of explosion in flue gas ducting was due to smoldering of

bagasse heap over the pin-hole grate of furnace and fine unburnt deposit
in the flat surfaces of the flue gas ducting for about 25 minutes due to
power failure, when alkali boil out operation was in progress in the boiler.
Smoldering of fuel / unburnts over the grate, in ash hoppers or flue gas
ducts results in generation of combustible carbon monoxide, which will
catch fire and explode the moment it combines with rich oxygen and
ignition energy.
It should be noted that when smoldering bagasse / fire wood / fuel is left
without flame over the grate for considerable duration due to power
failure or any other reasons, explosive carbon monoxide will generate and
accumulate in the flue gas system. The moment the carbon monoxide
comes in contact with rich oxygen and ignition energy, it will catch fire
and explode.
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2.0 Suggested precautions to be observed while commissioning the Bagasse

fired boiler to prevent explosions:
2.1 The boiler shall be operated with controls & instrumentation / DCS to
ensure that the essential safety interlocks and auto trip controls are on
and active.
2.2 It is essential to arrest all unintended leakage points in the ESP ash
hoppers and the entire flue gas ducting to ensure air tightness, before
light-up of boiler.
2.3 The air lock ash discharge valves of all ash hoppers or ash handling
system of ash hoppers must be in working condition prior to starting of
the ID fan. This is to prevent accumulation of carried over bagasse or
fine fuel particles in ash hoppers, which may cause internal firing or
smoldering.
2.4 It is suggested to provide safety interlock such that the ID fans can be
started only when the air lock ash discharge valves of various ash hoppers
/ ash evacuation system are working. This is to avoid accumulation of ash
/ un-burnt inside the ash hoppers. Sometimes, interruption in power
causes stoppage of air lock ash discharge valves in the ash hoppers. If
these valves are not re-started consciously again when power resumes,
ash accumulation may occur in the hoppers, which may lead to accidents.
Hence, failsafe system must be in place to re-start the air lock ash
discharge valves of hoppers / ash evacuation system of hoppers as and
when there is interruption in power.
2.5 The level sensors of the ash hoppers of ESP and associated instruments
like indicators, alarms and hooter must be in working condition. The ash
hoppers of ESP should be empty all the time by continuous evacuation of
ash.
2.6 The oxygen percentage in the flue gas shall not be allowed to exceed 6 -
8%.
2.7 Smoldering should not be allowed to take place in the furnace grate / ash
hoppers.
2.8 Bagasse heap shall not be allowed to form over the grate surface during
start up and pre-commissioning of boiler.
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2.9 The boiler shall not be stopped with smoldering bagasse heap over the
grate surface.
2.10 In case of stoppage of boiler due to power failure, the operation of the
boiler should be resumed as early as possible with alternate source of
power. The ID fan should run for minimum 5 minutes to purge the entire
flue gas ducting of possible accumulated combustible gases due to
smoldering of fuel over the grate and en-route, before starting the SA,
FD fans and fuel feeders.
2.11 If immediate continuation of boiler operation is not possible during power

failure condition, it is suggested to dump the smoldering fuel heap, if any,
from the grate top to ash hoppers. Ensure that the burning fuel and ash
is quenched well as it comes out of the ash hoppers to prevent damage to
conveyors en-route or working personnel.
2.12 If it is not possible to dump the smoldering fuel heap from the grate top
for some reasons or the other, the option of quenching the smoldering
fuel heap can be exercised. The water for quenching of fire should be as
minimum as possible to avoid unnecessary flooding of the grate and
hopper / duct below.
***
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Avant-Garde Engineers and Consultants Private Limited

1.0 Note on explosion incident in flue gas ducting during start-up /

Explosion in Electro Static Precipitator (ESP)

One case of explosion in flue gas ducting was due to smoldering of

2.0 Suggested precautions to be observed while commissioning the Bagasse

2.11 If immediate continuation of boiler operation is not possible during power

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