Experience with operating CFB Boilers

Sunil Kumar Singh Kanoria Chemicals & Industries Ltd. Power Generation Division

Presented to: Seminar on Operation & Maintenance of Captive Power Plants,

12-13 March, 2010 at DCW Auditorium, Sahupuram, Tuticorin

Circulating Fluidising Bed Combustion Boiler-1 (Yr: 1997)

Circulating Fluidising Bed Combustion Boiler-2 (Yr: 2005)

Abstract
The paper provides operation & maintenance experience in CFB boiler process featuring a two-stage solids collection system, introduction of RDZ and wing wall panels in Boiler-2. Those concern solids collection system, erosion protection and effective utilization of heat generated in the furnace.

Background
The major distinction between circulating fluidized bed (CFB) boilers installed at KCI is the type of the secondary solids separator. Both boilers feature a two-stage solids separator with a primary stage being an impact solids separator located at the furnace exit and collecting the bulk of the solids (95-97%) that are returned to the furnace by gravity. The primary separator is arranged as an array of U-shaped vertical elements (Ubeams). Two rows of in-furnace U-beams and four rows of external U-beams with all solids internally recycled within the furnace in this separator.

Background
The secondary separation stage, in Boiler-1 is installed below Air Pre Heater with impact separator located at hopper exit and collecting solids. The fine particles are conveyed to top mounted makeup ash silo via lean phase conveying system using blowers. In Boiler-2 there is typically a multicyclone dust collector (MDC), which is located in the lower gas temperature region of the boiler convection pass, i.e., 250 C. The fine particles collected by the secondary separator are returned to the furnace via gravity transport system.

U-beam primary separators

1
1. Sidewall/ membrane panel 2. U-beam - SS309H 3. Seal baffle 4. Refractory
Flue Gas & Solid Flow

4 3

Flue Gas

U Beams (Looking from furnace bottom)

Boiler Solids Flow

A. Fuel entering the furnace B. Upward solids flow C. Solids reflected by roof D. In-furnace U-Beam recycle E. External U-Beam recycle F. Multi cyclone recycle G. Fine ash not captured by multi cyclone H. Bed drain

Particle Collection System

Primary Particle Collection System Particle Transfer Hopper

Solids Collection Schematics

Multi cyclone Secondary Collector

Individual Gas Outlet Hoods

Ni- hard cyclone tubes Outlet tube life: 2 Yrs. Vanes & Inlet tube life: 3 Yrs

Access for Inspection

High Hardness Collection Components

Mechanical Dust Collector

Hot flue gas enters into inlet conical tubes Turning vanes create cyclonic effect Particles get entrained at the bottom Flue gas exit through outlet tube under induced effect The cyclone sleeves and spin vanes are made of high hardness (550 BHN) cast iron. MDC as secondary separator in Boiler-2 catches remaining solids and leaves fly ash to pass ESP through Air Pre Heater. KCI has not witnessed severe erosion of APH tubes in last 5 years of operation.

Reduced Diameter Zone (RDZ) panel for erosion protection at the upper refractory edge.
Furnace Wall (inside)

Division Wall

Boiler Availability
Boiler No. Start-up year Years accounted Forced outages, % Planned outages, % Availability, % Boiler-1 1997 98-09 4.4 9.0 86.6 Boiler-2 2005 05-09 2.3 6.0 91.7

Reliability
U-beam experience After 10 years of Boiler-1 (1997) regular operation, signs of U-beam mechanical degradation observed where the maximum temperatures or maximum solids loading occur. Some U-beam channels began to flare, and the mid-section of several U-beams rotated up to 10 degrees from the original position. Also, several erosion spots were found in rear-most rows of U-beams. KCI has now introduced mistake proofing that eliminate further coal feeding once U-beam temperature reaches beyond acceptable limit i.e. 920 deg C. The current operating philosophy thus avoid these degradations caused by high temperature operation. KCI replaced first two rows of U-beams (27 Nos.) in the Year 2007 of Unit-1 Boiler.

Reliability
MDC experience At KCI, due to the coal's high ash content and abrasiveness, about 50% of the MDC internal elements made of high hardness cast iron are being replaced during each yearly outage to avoid a loss of MDC efficiency. KCI has installed few elements made of ceramics under consultation with OEM to establish the performance in the Sep 2007 and during last yearly outage no wear was found on any of the ceramic elements. Solids collected in MDC hoppers are recycled to furnace via variable speed, rotary valves feeding ash to air slide (gravity transport system). MDC hoppers maintains ash inventory required for furnace temperature control. This do not require air blowers to convey secondary ash to Makeup silo, as in Boiler-1, contributing significant reduction in auxiliary power consumption.

Reliability
Air Slide Experience: At MDC hopper, where air slide ash conveyors are used, frequent maintenance work was needed on the return system. Spillage of ash starts from the air slide flanges in spite of replacement of gaskets duly applied with silicon based sealant. These leakages are being arrested temporarily by applying sodium silicate on leaking portion. Variable speed, rotary valves are used at the MDC hopper discharge(s) to control the flow rate of recycled solids. Ash spillage from the glands of Rotary valve starts every 2 to 3 months after replacement of asbestos graphite packing. KCI has provided low pressure purge air for gland cooling to increase packing life.

RDZ experience

Reliability

Boiler-1 refractory interface is prone to erosion as solids falling down the wall along the surface profile of tube panel do not maintain continuity adjacent to tube. To avoid the panel erosion, KCI raises refractory height by 50 MM in every annual shutdown to protect the wall thickness. After a span of 3 years, raised refractory is removed and adjacent panels are metal coated with an erosion protection layer. RDZ panels introduced in Boiler-2 consists of a reduced diameter tube section mating to a specially shaped ceramic tile. These panels eliminate the discontinuity of solids falling down adjacent to the tubes thereby reducing refractory interface maintenance requirements. KCI has prolonged renewing of tube protective coating above refractory interface, from 3 years to 5 years, based on the condition of metal coating layer observed in Boiler-2 furnace.

Reliability
Wing Wall experience KCI witnessed bowing of wing wall (S-shaped) in July 06 during annual inspection when, deflection of about 150 MM was observed in the panel. The wing walls are located inside furnace and are welded to top and bottom header. These do not have any spring hanger to absorb thermal expansion difference corresponding to furnace tube panel. It was concluded that sudden drop in water level reached when boiler shuts down, caused water starvation in wing wall panel, which was compounded by radiation from hot U-beams causing bending of the same. Bowed wing walls have not caused any immediate problems till date. As a measure of precaution, KCI inspects the wall regularly to verify that wear is not occurring.

Conclusions
RDZ panels have reduced refractory interface maintenance requirements. MDC as secondary solid collector has ability to better control furnace temperature. Residence time of fine carbon has increased. Erosion rate of APH tubes and auxiliary power consumption in ash recycling system has reduced. U-beam temperatures are on lower side as wing wall panel in boiler-2 has advantage of high furnace heat transfer rate. We take advantage of the lower maintenance costs and auxiliary power requirements in operating Boiler-2.