CFBC Boiler Gyanendra Sharma NPTI Delhi

CFBC Boiler
Gyanendra Sharma
• Future utilization of oil and coal in utility and industrial power
stations depend on combustion systems which meet the
requirement of an extensive reduction of emission
• One solution with economical benefits is:
Circulating Fluidized Bed Combustion
03/27/2021 Gyanendra sharma - NPTI Delhi 2

001 656p
History
Two CFB technologies have been developed

• One origin was a bubbling bed burning low grade fuels
• The other origin were gas/solid reactors for process technology applications
End of 70ies first applications in coal combustion
Break through
• in the 80ies due to environmental legislation
Typically 200 mg/m³ NOX and 200 - 1,000 mg/m³ SO2 became mandatory
• later due to utilisation of opportunity fuels

141 267p
Relationships
between Fixed Grate, Fluidized Bed, and
Pulverized Firing
S to k e r F ir in g F lu id iz e d B e d F ir in g P u lv e r iz e d F irin g
(F ix e d B e d ) BFB C FB (E n tr a in e d B e d )
G as
G as
G as
G as
Fu e l Fu e l & A ir A ir
S o rb e n t Fu e l & Fu e l
S o rb e n t
A ir A s h A ir A s h A ir A s h A sh
V e lo c ity 8 - 1 0 ft/ s e c 4 - 1 0 ft/ s e c 1 5 - 2 3 ft/ s e c 1 5 - 3 3 ft/ s e c

(2 .3 - 3 .0 m / s ) (1 .2 - 3 .0 m / s ) (4 .6 - 7 .0 m / s ) (4 .6 - 1 0 .0 m / s )
A ve ra g e Be d
6 ,0 0 0 m 1 ,0 0 0 m 1 0 0 - 3 0 0 m 5 0 m
P a r tic le S iz e
056 338p
CFB technology generates power :
 Environmentally friendly
 High SO2 capture
 Low NOx emissions
 Firing a wide variety of different fuels

SO2 Capture
 SO2 Capture achieved by Optimum temperature :

850 °C
limestone injection
SO2Capture efficiency
CaCO3 --> CaO + CO2
CaO + SO2 + ½ O2 --> Ca SO4
Furnace temperature control is

very critical
Limestone consumption varies 800 850 900

enormously with furnace temperature T (°C)

NOx Emissions
 NOx Emissions influenced by

3 main parameters :
NOx
- Combustion temperature
- N2 in fuel
- Excess air and staggering T (°C)

800 1 000 1 200

General Process
Flue gas
 Bed temperature
Optimum
temperature :
850 °C
Coal
Temperature maintained by heat

pick up in exchange surfaces
Either in furnace
Or in FBHE
Air Air
Ash
Air
CFB Boilers
1
8
7 9
3
2

Concept
Main Design Criteria
 High bed inventory of fine particles
 High recirculation rate
 Highly efficient cyclones
 External and/or Internal heat exchangers for temperature control

depending upon the application

Concept
External Heat Exchangers
Advisable when :
 A very fine tuning of the bed temperature is necessary
 Fuel Analysis leads a small furnace

( Petroleum coke , Anthracites )
 Very large electrical capacity CFB
 Highly abrasive fuels

FBHE Design
Cyclone Furnace
FBHE

FBHE Design
Ashes from
Ashes to cyclones
furnace
03/27/2021
Fluidisation air
Gyanendra sharma - NPTI Delhi 13
Wing Walls
to cyclone
Could be used as
• Evaporator
• HP superheater
• Final reheater
Tube -fin-tube
de sign
Erosion prote ction

(re fra tory)
Furna ce
Omega Panels
View from top
Platen heaters within the furnace are a powerful

feature:
• To extract heat for superheating from the furnace

• To have a self controlling system for furnace heat
extraction (no mechanical control means needed)
• To avoid erosion of heating surfaces by installation in
the vertical flow area of the furnace and smooth surface
design
First unit has now gathered more than 100 000 h

operation with first platen heater equipment.
Double Super Welded Design

Omega Design

CFD Analysis
of Cyclone
Performance

006 056px
Fractional Collection
Efficiency of Collection
Systems
(Results from Simulation)
120%
100%
80%
Collection efficiency
Cyclone
60%
40%
a lte rna tive colle ction syste m
20%
0%
0 50 100 150 200 250
d [µm ]
056 287p
Cyclone Improvement
Measures Se cond Pa ss
Ecce ntric Vorte x
Finde r Arra nge me nt
Downwa rd
Incline d Adva nce d Vorte x
Inle t Duct Finde r Sha pe
High Pe rforma nce

Re fra ctory for Inle t Are a

056 329p
Particle Size
Distribution
ofNew
(Old and
0.1
Solid
CycloneInventory
Design)
1.0
ne w cyclone de sign old cyclone de sign
(%)
1 0.0
2 0.0
3 0.0
4 0.0
5 0.0
6 0.0
7 0.0
8 0.0
Re sidue R
9 0.0
9 9.0
9 9.9
10 1 00 µm 1000
03/27/2021 Gra in- NPTI
Gyanendra sharma size dDelhi 19
056 330p
High Efficient Cyclone
Benefits
• Maximize fine solid recirculation
• Increase carbon burnout as well as limestone utilization
• Increasing solid concentration in the upper furnace leads to

• enhanced heat transfer
• perfect temperature homogenity
• Fine PSD of inventory and thus less erosions
• Minimize solids entrained to the backpass and thus

• less backpass erosion
• less backpass fouling
• lower CO generated in the backpass
056 343p
Cyclone Arrangements
< 1 00 MWe l 10 0 - 2 00 MWe l
20 0 - 30 0 MWe l 3 0 0 MW - 4 00 MWe l 6 0 0 MWe l

056 352p
125 MWe, 250 MWe and Beyond
+ + +
+ +
+ +
+ +
+ + +
Class 150 MW Class 350 MW Class 600 MW

Performance of CFB boilers
EMILE PROVENCE RED CAN GOLDENBERG AKRIMOTA TAMUIN

HUCHET HILLS
1991 1996 2001 2002 1992 2003 2002
OUTPUT 125 250 250 160 115 125 130

MWe
Coal Coal ( 4%S ) Lignite Lignite Brown coal Lignite Petcoke

FUEL Coal slurry Pitch
THERMAL > 89 % > 94 % > 93 % > 92 % > 89 % > 83 % (*) > 92 %

EFF.
DeSOx > 90 % > 97 % > 95 % > 95 % > 95 % > 95 % > 90 %
NOx < 200 < 250 < 250 250 <200 215 <200
mg/Nm3
(*) HHV basis

Emissions achieved CFBs
in Relation to the Fuel Type
Fuel Type NOX SO2 Desulphurization
Efficiency
mg/m³stp, 6 % O2 mg/m³stp, 6 % O2 %
Anthracite & Anthracite tailings 70 220 80
Petcoke 100 200 97
Slurry 110 140 95
Bituminous Coal 80 200 95
Eastern US Bituminous Coal 60 100 97
High Moisture Lignite 140 200 90
High Sulphur Lignite 160 200 97
Biomass 100 - -

058 180p
Ash Screw Cooler
Ash from Furnace

1560 - 1650 °F
850 - 900 °C
Ash to Bottom Ash

Handling System
400 °F / 200 °C
(Typical)

056 340p
Ash Screw Cooler
Details
Holo-Flite Screw
Heat Exchanger
Trough Jacket

056 341p
Water Cooled Ash
Cooler
Return to furna ce Ash inle t duct from
furna ce bottom
Conve yor a sh
Fluidizing a ir
to a sh silo
056 323p
Split Loop Seal
from Cyclone
Coa l
to Furna ce

056 232px
Utility Boiler
Major Recent References:
Power Station Mladá Boleslav

2 x 50 MW
Energy Supply for VW-Skoda Factory
• Technology - CFB
• Fuel - Bituminous
Coal
• Capacity t/h 2 x 140
• Design Pressure bar 145
• Temperature °C 535
• Commissioning - 1998
• Country - Czech Republic
• Customer - SKO Energo
012 188p
Power Station Cao Ngan,
2 x 50 MW
Longitudinal Section
+ 5 3 .0 m
Live Steam
115 bar (design pressure)
538 °C
66 kg/s (237.6 t/h)
Feedwater
223 °C
Fuel
Vietnamese Lean Coal
Customer
VINACOAL, Vietnam
03/27/2021 Gyanendra sharma - NPTI Delhi ± 0 .0 m 30

012 223p
Utility Boiler
Major References:
Power Station Ledvice

110 MW
CFB Fired Boiler in Czech Republic
• Fuel - Brown Coal
• Capacity t/h 350
• Country - Czech
Republic
• Customer - CEZ a.s.
012 183p
Utility Boiler
Major References:
Power Station Emile Huchet

125 MW
CFB Fired Boiler in France
Coal
• Temperature °C 545/540
• Country - France
• Customer - SODELIF
012 185p
Utility Boiler
Major References:
Power Station Goldenberg

125 MW
Extra large Furnace due to wet
(up to 60 % water) Brown Coal
• Fuel - Lignite
• Country - Germany
• Customer - RWE
012 187p
Akrimota,
Boiler with CFB
2 x 125 MW
+ 50.0 m
Live Steam
138 bar
538 °C
405 t/h
Reheater Steam
36 bar
537 °C
375 t/h
Feedwater
247 °C
Fuel
High Sulphur
Lignite
03/27/2021 Gyanendra sharma - NPTI Delhi

± 0.0 m 34
012 217pÄ
Utility Boiler
Major References:
Power Station Tamuin

2 x 130 MW
CFB Fired Boilers in Mexico
• Fuel - Petroleum Coke
• Country - Mexico
• Customer - SITHE-IPG

012 184p
Utility Boiler
Major References:
RF#1&#2
2 x 150 MW
CFB Fired Boilers in Taiwan
• Fuel - Petroleum Coke
• Country - Taiwan
• Customer - FHI

012 198p
Utility Boiler
Major Recent References:
+ 5 6 .7 m
Power Station Çan
2 x 160 MW
First CFB Fired Boilers in Turkey
• Fuel - Lignite
• Country - Turkey
• Customer - TEAS

012 154p
Utility Boiler
Major References:
Tonghae Thermal Power Plant

2 x 220 MW
Reheat CFB Boilers in
Republic of Korea
• Fuel - Anthracite
• Commissioning - 1998 and 1999
• Country - Republic of Korea
• Customer - Tonghae
011 422p
Utility Boiler
Major References:
Power Station Provence

250 MW
First 250 MW CFB Boilers in the world
• Fuel - Bituminous Coal
• Country - France
• Customer - SOPROLIF

011 424p
Utility Boiler
Major References:
Power Station Red Hills

2 x 250 MW
• Fuel - Lignite
• Country - USA
• Customer - Choctaw Generation

011 459p
Utility Boiler
Major References:
Power Station Guayama

2 x 250 MW
Reheat CFB Boilers in Puerto Rico
Coal
• Country - Puerto Rico
• Customer - AES
011 423p
250 MW CFB for
Indian
3 D Model
Lignite

011 475p
Fuels for
Circulating Fluidized
Beds
N CV Wa te r co nte nt Ash co nte nt Sulph ur
MJ/ kg We ig ht % a .r. We ig h t % a .r. % ma f
Anthra cite 16 8 37
Bituminous coa l 19 - 29 7 - 24 3 - 25
Lignite 12 - 18 12 - 4 2 12 - 2 6 5 .5 - 1 2
Brown coa l 8 - 12 35 - 5 8 1 - 40 1 - 13
Spe cia l fue ls:
Pe tcoke < 31 .0 < 5 < 1 < 7
Wood chips 12 36 2
Coa l slurry 1 0 .5 33 30
Pa pe r sludge 2.4 62 15
Se wa ge sludge 0.6 73 15
Ba rk 9 - 16 15 - 5 0 1 - 3 (20 )

056 295p
Reference Summary
• Fuels
Coal and lignite
Water content up to 60 %
Ash content up to 40 %
Sulphur content up to 13 % maf
various opportunity fuels
(coal, slurry, sewage sludge, petcoke, bark, ...)
• Water/Steam side
Natural circulation
Assisted circulation
Once-through (engineering study)
With/without reheat up to 560 °C
• Capacity
From 70 MWth up to 250 MWel
600 MWel under investigation
141 269p
Advantages of CFB
for High Sulphur Lignite
• Desulphurization of > 97 % achievable
• Reduced slagging tendency in the furnace

– No slagging due to pyrite of other sulphur components
– Reduced fouling in the backpass due to low
temperature
and even temperature profile
• Higher boiler efficiency

– Marginal SO3 in flue gas due to SO3 capture by
limestone
056 374p – Therefore, flue gas exit temperature of 140 °C or less
Lignite
Conclusion
Fired CFB Plants
• Sulphur content of 14 % (daf) commercially utilized in CFB
• Desulphurization of > 97 % achievable
• Special attention must be given to cyclone performance
• Equal fuel / air / limestone feeding into the furnace must be
ensured under all operating conditions
• Intensive testing is highly recommended:
– mine operation
– coal analysis with emphasis on type of sulphur
– available limestone sources and limestone reactivity
– combustion tests give valuable results
056 377p
Summary
• CFB technology is well developed today
More than 300 CFB plants are operating or are under construction
Plants with 250 MW capacity are running since 1995
• CFB technology meets environmental requirements

NOX values less than 200 mg/m3 s.t.p. and desulphurization
efficiencies higher than 97 % could be achieved
• CFB techhnology is able to burn a wide range of fuels

Especially high sulphur and/or high ash or high water coals could be
utilized
001 673p

CFBC Boiler Gyanendra Sharma NPTI Delhi

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CFBC Boiler Gyanendra Sharma NPTI Delhi

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CFBC Boiler

• One solution with economical benefits is:

Circulating Fluidized Bed Combustion

03/27/2021 Gyanendra sharma - NPTI Delhi 2

Two CFB technologies have been developed

End of 70ies first applications in coal combustion

03/27/2021 Gyanendra sharma - NPTI Delhi 3

V e lo c ity 8 - 1 0 ft/ s e c 4 - 1 0 ft/ s e c 1 5 - 2 3 ft/ s e c 1 5 - 3 3 ft/ s e c

 High SO2 capture

 Low NOx emissions

 Firing a wide variety of different fuels

03/27/2021 Gyanendra sharma - NPTI Delhi 5

 SO2 Capture achieved by Optimum temperature :

CaO + SO2 + ½ O2 --> Ca SO4

Furnace temperature control is

Limestone consumption varies 800 850 900

03/27/2021 Gyanendra sharma - NPTI Delhi 6

 NOx Emissions influenced by

- Excess air and staggering T (°C)

03/27/2021 Gyanendra sharma - NPTI Delhi 7

Temperature maintained by heat

03/27/2021 Gyanendra sharma - NPTI Delhi 9

Main Design Criteria

 High bed inventory of fine particles

 High recirculation rate

 Highly efficient cyclones

 External and/or Internal heat exchangers for temperature control

03/27/2021 Gyanendra sharma - NPTI Delhi 10

External Heat Exchangers

 A very fine tuning of the bed temperature is necessary

 Fuel Analysis leads a small furnace

 Very large electrical capacity CFB

 Highly abrasive fuels

03/27/2021 Gyanendra sharma - NPTI Delhi 11

03/27/2021 Gyanendra sharma - NPTI Delhi 12

Erosion prote ction

View from top

Platen heaters within the furnace are a powerful

• To extract heat for superheating from the furnace

First unit has now gathered more than 100 000 h

Double Super Welded Design

03/27/2021 Gyanendra sharma - NPTI Delhi 15

03/27/2021 Gyanendra sharma - NPTI Delhi 16

High Pe rforma nce

03/27/2021 Gyanendra sharma - NPTI Delhi 18

• Increase carbon burnout as well as limestone utilization

• Increasing solid concentration in the upper furnace leads to

• Fine PSD of inventory and thus less erosions

• Minimize solids entrained to the backpass and thus

20 0 - 30 0 MWe l 3 0 0 MW - 4 00 MWe l 6 0 0 MWe l

03/27/2021 Gyanendra sharma - NPTI Delhi 21

Class 150 MW Class 350 MW Class 600 MW

03/27/2021 Gyanendra sharma - NPTI Delhi 22

EMILE PROVENCE RED CAN GOLDENBERG AKRIMOTA TAMUIN

OUTPUT 125 250 250 160 115 125 130

Coal Coal ( 4%S ) Lignite Lignite Brown coal Lignite Petcoke

THERMAL > 89 % > 94 % > 93 % > 92 % > 89 % > 83 % (*) > 92 %

DeSOx > 90 % > 97 % > 95 % > 95 % > 95 % > 95 % > 90 %

(*) HHV basis

03/27/2021 Gyanendra sharma - NPTI Delhi 23