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Jayaraman Rajavel
Thermax Ltd., Pune
Outline
Concept of IR-CFBC boiler Comparison between CFBC and AFBC boiler technologies Features of IR-CFBC design Comparison of various CFBC technologies
Fluidization concept
Fluidization concept
EFFECTIVE REDUCTION OF Sox EMISSIONS THROUGH LIME INJECTION REDUCTION OF NOX FORMATION BY REDUCED THERMAL NOX GENERATION REDUCED CO EMISSION LEVELS FUEL FLEXIBILITY
CFBC.PPT-8
Emission..
Controlled combustion temperature Sox control through Lime addition Nox control through lower operating temperature Staging of combustion Lower excess air utilization
Fuel Flexibility.
COAL LIGNITE WASHERY REJECTS CHAR PETCOKE BIOMASS INDUSTRIAL REJECTS (CHAR ,ETP SLUDGE ETC). OIL GAS
Volatile Ash,
Heating
Moisture,
Use Fuel
of lower rank fuels reduces fuel costs flexibility - minimizes fuel supply uncertainties to burn low cost and waste fuels
Ability
B&W Internal Recirculation - Circulating Fluidized Bed Combustion Boilers A simplified approach to improved flexibility and reliability Design Features High combustion efficiency Compact, economical design Higher reliability and availability Lower maintenance costs Reduced erosion Fuel flexibility Low emissions
U-Beam Separators
1
1. Sidewall membrane panel 2. U-beam - SS309H/ SS310H/RA253MA 3. Seal baffle 4. Refractory
4 3
Flue Gas
U-Beam Separators
SEGMENTAL U BEAMS
U-Beams
90
Efficiency, %
80
70
60
50
40 0 20 40 60 80 100 120
overall solid collection efficiency ~ More than 99.7% Precise furnace temperature control ~ By controlling solid recycle rate from the secondary collector Extended turndown ratio without use of auxiliary fuel (oil/gas) ~ 100% to 20% MCR Low auxiliary power requirements compared to cyclone-based CFBC technologies ~ 2-4 w.c. (50-100 mm w.c.)
Low gas velocity through U-beam collector significantly reduces need for refractory
Hot-Cyclone
Single-stage (100% efficiency for particles of d>100 micron)
Integral Cyclone
Single-stage (100% efficiency for particles d>100 micron)
Cold-Cyclone
Single-stage (100% efficiency for particles of d>100 micron)
* Recycling finer particles increases furnace heat transfer rate, improves combustion efficiency and limestone utilization. Upper Furnace Density lb/ft3 (kg/m3) Furnace Temperature Control 0.7 1.0 (11 16) Desired temperature can be maintained within +/10 F interval for wide range of fuels and operating conditions by adjusting secondary recycle rate. 5:1 0.5 0.7 (8 11) Temperature is predetermined by furnace and heat exchanger design along with fuel and limestone properties and sizing. 3.5 : 1 0.5 0.7 (8 11) Temperature is predetermined by furnace and heat exchanger design along with fuel and limestone properties and sizing. 3.5 : 1 0.3 0.5 (5 8) Lower bed temperature is controlled by adjusting cold cyclone ash recycle rate. Temperature span across furnace height is up to 200 F. 3.5 : 1
Boiler Turndown Without Auxiliary Fuel Refractory: Thickness, in. (mm) Covered Areas
0.6 2.0 (15 50) Lower furnace, U-beam zone enclosure walls None 15 18 (4.9 5.5) 21 23 (6.4 9.8) Not required 4 (1.0) (U-beams + MDC) Lower
~3 (~75) on studded tubes 8-12 (200-300) on casing Lower furnace, cyclone recycle loop (5 10 times more than @ B&W CFB) 3 5 per cyclone 16 18 (4.9 5.5) 75 85 (22 26) Required for J-valves 6 8 (1.5 2.0) Higher
~3 (~75) Lower furnace, cyclone recycle loop (3 5 times more than @ B&W CFB) Number varies with arrangement 16 18 (4.9 5.5) 75 85 (22 26) Required for J-valves ~6 (~1.5) Higher
~2 (~50) Entire furnace, cyclone (3 4 times more than @ B&W CFB) None 13 15 (4.0 4.5) N/A N/A Required for siphons 4 6 (1.0 1.5) Moderate
Hot-Temperature Expansion Joints Furnace Shaft Velocity [Design Range] , ft/s (m/s) Furnace Exit Velocity, ft/s (m/s) High-Pressure Air Total Pressure Drop Across Solids Separator(s), in. wc (kPa) Auxiliary Power Consumption
upper furnace heat transfer rate and precise furnace temperature control
AND
Extended
MCR
Are both the result of the B&W IR-CFB two stage solids collection / recycle system characteristics
Low
80%+ of bed material is drained during cooldown. Can shutdown / cool / enter / re-start within a 24 hour period compared to 2 to 3 times longer for other CFB design types
Low
Maintenance Costs
No refractory maintenance, no hot expansion joints, no fluidized sealing system, low furnace exit velocity, low gas velocity in convective heating surfaces
- MORE THAN 95 % BY U - BEAMS - NO MAINTENANCE HIGH TEMP WITHSTAND CAPACITY ( 940deg.C) - ALLOWS QUICK START UP - LESS OIL CONSUMPTION
LESS REFRACTORY WORK (Only 15% as compared to cyclone design CFB) WITH CYCLONE DESIGN CFBs LOWER POWER CONSUMPTION LOW GAS VELOCITY
Draft loss across U-BEAMS - 1 INCH Draft loss across CYCLONE - >5 INCH
- IN U-BEAM AREA 5 TO 6 m /s - CYCLONE INLET 20 TO 25 m / s - FASTER LOAD RESPONSE - FURNACE TEMP. IS MAINTAINED TO BOTTOM OF FURNACE - FD AIR COOLES BED ASH IN FLUID BED BED ASH COOLER - PARTICULATE COLLECTION EFF. OF U-BEAMS IMPROVES AT PART LOADS - FUEL IS INJECTED TO FURNACE WITH FD AIR PRESSURE
CONTROLLED EXTERNAL FLY ASH RECYCLE WITHIN +/- 15 DEG.C FROM TOP
HIGH INTERNAL CIRCULATION Improved furnace performance High operating efficiency LOW EXTERNAL CIRCULATION No J valve / L valve Finer control on performance COMPACT PRIMARY COLLECTOR Small footprint area Boiler plant size reduced NO THICK REFRACTORY Quick start up TOP SUPPORTED INTEGRATED UNIT No hot expansion joints Reduced maintenance UNIFORM LOW VELOCITY IN FURNACE & SUPERHEATER CFBC.PPT-7 Reduces potential for erosion Reduced maintenance
LESS USE OF REFRACTORY (TYPICALLY 75 TONS VS 450) (NO THICK REFRACTORY) FLUID BED ASH COOLER - NO MOVING PARTS AIR -SWEPT COAL FEEDER- NO MOVING PARTS METAL COATING / RDZ FOR REFRACTORY INTERFACE- COUNTERS EROSION BETTER S/H SUPPORT SYSTEM USED FOR ENHANCED RELIABILITY - NO SLINGER TUBES PRONE TO EROSION DENSE STUDS PATTERN (96 per Ft2)- BETTER HEAT TRANSFER - BETTER REFRACTORY ADHERENCE NO REFRACTORY LINED DIP - LEG, J, L VALVE HIGH MAINTENANCE ITEM ELIMINATED TRADITIONAL PENDANT VERTICAL LEG SUPERHEATER - NO FOULING NO SOOT BLOWERS REQUIRED - LESS MAINTENANCE -SAVING IN BLOW STEAM LOW GAS VELOCITY IN CONVECTION PASS. NO EROSION OF PRESSURE PARTS LOW GAS VELOCITY AND IN-LINE ARRANGEMENT OF ECONOMISER AND AIR HEATER TUBES REDUCED EROSION POTENTIAL ASH RECYCLE SYSTEM (MDC) GIVES FASTER LOAD CHANGE RESPONSE. LOWEST NOX EMISSION LEVEL IN THE INDUSTRY -<100 PPM
THANKS