Hindawi Publishing Corporation

Journal of Combustion
Volume 2013, Article ID 438384, 12 pages
http://dx.doi.org/10.1155/2013/438384

Research Article
Influence of Sorbent Characteristics on Fouling and
Deposition in Circulating Fluid Bed Boilers Firing High Sulfur
Indian Lignite

Selvakumaran Palaniswamy,1 M. Rajavel,1 A. Leela Vinodhan,1

B. Ravi Kumar,1 A. Lawrence,1 and A. K. Bakthavatsalam2
1
Bharat Heavy Electricals Limited, Tiruchirappalli, Tamil Nadu 620 014, India
2
National Institute of Technology, Tiruchirappalli, Tamil Nadu 620015, India

Correspondence should be addressed to Selvakumaran Palaniswamy; [email protected]

Received 9 August 2013; Revised 28 September 2013; Accepted 1 October 2013

Academic Editor: Michael Fairweather

Copyright © 2013 Selvakumaran Palaniswamy et al. This is an open access article distributed under the Creative Commons
Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is
properly cited.

125 MWe circulating fluidized bed combustion (CFBC) boiler experienced severe fouling in backpass of the boiler leading to
obstruction of gas flow passage, while using high sulfur lignite with sorbent, calcium carbonate, to capture sulfur dioxide. Optical
microscopy of the hard deposits showed mainly anhydrite (CaSO4 ) and absence of intermediate phases such as calcium oxide or
presence of sulfate rims on decarbonated limestone. It is hypothesized that loose unreacted calcium oxides that settle on tubes are
subjected to recarbonation and further extended sulfation resulting in hard deposits. Foul probe tests were conducted in selected
locations of backpass for five different compositions of lignite, with varied high sulfur and ash contents supplied from the mines
along with necessary rates of sorbent limestone to control SO2 , and the deposits build-up rate was determined. The deposit build-
up was found increasing, with increase in ash content of lignite, sorbent addition, and percentage of fines in limestone. Remedial
measures and field modifications to dislodge deposits on heat transfer surfaces, to handle the deposits in ash conveying system, and
to control sorbent fines from the milling circuit are explained.

1. Backdrop content of 15 to 35%, sulfur content of 1.0 to 7.0%, and

moisture content of 10 to 45%. The varieties found in Gujarat
India with growing energy consumption is looking at utiliz- and Rajasthan region have moderate to high sulfur (1 to
ing all its potential energy resources in the most economic 7%) content. It has become an economic necessity to use
and environmentally sustainable manner. Coal will continue these lignites for power generation in view of spurt in energy
to be the major energy source in India due to its availability. demand, with SO2 emission controlled. Circulating fluid
Per capita consumption of electricity and GDP growth has bed combustion (CFBC) technology is employed considering
direct relation, and energy intensity in developing countries the impurities, moisture, ash, and sulfur content and wide
like India is comparatively more than the developed world, variations in lignite. Hence, the share of lignite-based pit head
and the gap between supply and demand is ever increasing. thermal projects in Gujarat and Rajasthan is increasing. The
The demand for all forms of energy is expected to increase size of CFB boilers in India using lignite has reached already
substantially in the foreseeable future and is expected to get over 250 MWe and set to increase above 500 MWe, and that
doubled by 2030. Although coal would continue to be a underlines the importance.
major energy source in India due to its availability, lignite Slagging, fouling, and ash deposition are major problems
is fast emerging as an alternate source of fuel for electricity experienced in PF boilers. In contrast, agglomeration of bed
generation. In India, the total lignite potential is 4177 million particles in fluidized bed combustion system is considered
tonnes. Indian lignites have a typical analytical range of ash as a primary operational issue. Interaction and coalescence
2 Journal of Combustion

of bed particles and ash (sintering) are considered to be the the initial period of operation. These deposits increased
principal sources of agglomeration in CFB boilers employing gas-side pressure drop and in turn increased loading of
bed material and fuel ash as binary system. Choking/blocking induced draught (ID) fans, with high current, causing boiler
in fuel path is another peculiar operational problem expe- trips.
rienced worldwide in CFB boilers, firing pet-coke, low rank Consequently, CFB boiler was required to be operated
coals, and biofuels [1]. with less quantity of limestone which resulted in more sulfur
Lignite mineralogy greatly influences combustion behav- dioxide emissions. The fouling took place mostly in LTSH
ior. Agglomeration and clogging/blocking are experienced coils of backpass which is placed between reheater and econ-
due to sintering of lignite ash with limestone (sorbent) at omizer. Due to fouling in the backpass, fly ash particles
lower temperature regime in which CFB boilers operate collected in hoppers of economizer and in other zones got
(640–960∘ C). At this low temperature range, the extensive sintered during intermittent storage. Nonoperation of soot
knowledge built with respect to slagging, fouling, and cor- blowers (SB) and water ingress while starting soot blowing
rosion phenomenon occurring at higher temperatures in caused cakes formation. Dislodgement of such cakes leads
pulverized fuel combustion may not be applicable. In CFB to difficulty in ash evacuation. Deashing system pump was
boilers, ash sintering contributes to deposit formation in chocked often, due to sintered particles (lumps) formed due
cyclone, return leg, and postcyclone flue gas channel (back- to water ingress.
pass) [1]. In operating units, rapid sintering lead to heavy
agglomerate formation, which finally inhibited circulation in 3. Experiments: Laboratory and Field
dense phase areas (such as seal pot) and in the backpass.
Understanding the sintering behavior of fuel is required for 3.1. Lignite. Six samples (sample 1 to sample 6) of high
resolving such problems. sulfur lignite collected from Giral/Rajasthan/India (covering
Over the past decades, designers and operators of flu- a range of high sulfur content) are considered for the present
idized beds have been concentrating on developing the CFBC study of backpass fouling propensity of the high sulfur fuels
technology by establishing the optimum operating conditions in CFB boiler. All the fuel samples are prepared in accordance
and troubleshooting associated with refractory and so forth. with ASTM-D 2013. The as-received solid fuels are crushed
Due attention has not been paid to understand the limestone to pass a number 4 sieve (4.75 mm) and then air dried
characteristics that are important for efficient capture of SO2 . until the loss in weight is not more than 0.1% per hour.
Present work describes influence of limestone and its grain size Air dried samples are again crushed to pass a number 72
in blocking/clogging of cyclone and hard deposits in second pass mesh (212 microns). Samples of sizes less than 72 mesh are
of CFB boiler during combustion of high sulfur lignite with high used for analyses of proximate, ultimate, and calorific values.
ash content (20 to 30%) in CFB units in Giral, Rajasthan state Adequate quantity of ash of each fuel is generated using
of India. proximate analyses at 750∘ C for further analyses of chem-
ical composition, ash fusion temperature. The proximate,
2. Operational Issues ultimate, and gross calorific values of the samples were
carried out using TGA 701 proximate Analyzer (LECO),
High sulfur content lignite, available at Giral, Barmer District, Elemental analyzer Vario EL III, and PARR Isoperibol Bomb
and Rajasthan state, is used as fuel. These lignites had posed Calorimeter, respectively. The chemical composition of ashes
several operational issues during initial stage of commission- was carried out by ICP- AES, Perkin Elmer.
ing and stabilization. High sulfur in the lignite needs high
limestone feed rates to control emissions. High limestone feed 3.2. Limestone. The sorbents are characterized based on
rates caused huge quantities of backpass deposits, which led the CaCO3 content, particle size distribution of the parent
to obstruction of gas flow passage. Despite providing steam sorbent, and a relative sulfation reactivity parameter [3].
soot blowers for clearing the deposits obstruction of gas flow Calcium utilization, in general, increases as the sorbents
increased with increase in limestone feed rate. particle size decreases. As the particle size distribution of the
feed sorbent changes in a CFB due to attrition, it is taken for
2.1. Cyclone Standpipe Blockage. During commissioning, ash granted that the feed size distribution of limestone (input) is
holdup occurred in cyclone standpipe at low loads of about not as important as the resultant sorbent size distribution in
20 to 40 MW. Ash analysis of the hold-up material is carried the boiler. On the contrary, mathematical model results show
out. that sulfur capture efficiency is related to particle attri-
tion/fragmentation of sorbent inventory in addition to input
2.2. Backpass Fouling. Sulfur dioxide emitted during com- particle size distribution to the performance of circulating
bustion is absorbed in situ by adding limestone of size less fluidized bed CFB combustors [4]. The physical and chemical
than 1.0 mm. The CFB boiler experienced fouling in super- properties of a sorbent are important when evaluating for
heater/reheater (SH/RH) coils while adding required quantity use in CFB application. Sorbents although chemically similar,
of limestone (Figure 1). Heavy and rapid deposit buildup has may have different sulfation performance. Extensive litera-
been experienced on the flue gas side of the heat transfer ture studies on process of desulfurization in CFBC show that
tubes. Deposit buildup was most severe at low temperature sorbent conversion degree is dependent not only on residence
superheater (LTSH)-SH 1B tube bank. Also, growth of ash time in combustor but also on its porosity, pore structure
deposit in final stage reheater tube bank was observed during and pore size distribution [5]. The detailed analyses of Indian
Journal of Combustion 3

Additional LRSB-2
nos above SH-III coil
at front side

Superheater-III

660 ∘ C–720 ∘ C

Reheater-II Top of superheater 1B left-before

Additional LRSB-4
nos between RH-2
banks

610 ∘ C–640 ∘ C Additional LRSB-2 nos

at existing manhole
door location between
RH-2 and SH-1B at rear
side

530 ∘ C–590 ∘ C

Superheater-IB
Existing manhole door
shifted in between LRSB
to accommodate
additional LRSB
Top of superheater 1B left-after

(a)

Additional LRSB-2
nos above SH-III coil
at front side

Superheater-III

660 ∘ C–720 ∘ C

Reheater-II Top of reheater first bank middle-before

Additional LRSB-4
nos between RH-2
banks

610 ∘ C–640 ∘ C Additional LRSB-2 nos

at existing manhole
door location between
RH-2 and SH-1B at rear
side

530 ∘ C–590 ∘ C

Superheater-IB
Existing manhole door
shifted in between LRSB
to accommodate
additional LRSB
Top of reheater first bank middle-after

(b)

Figure 1: Deposits in superheater/reheater coils before and after introduction of high pressure soot blowers and location of additional soot
blowers in backpass.

limestones-chemical composition, calcium and magnesium 3.3. Deposit Sampling Using Probes and Field Experiment
carbonate contents, that are used in CFB were performed
using Inductively Coupled Plasma-Atomic Emission Spec- 3.3.1. Deposit Probes. Field experiment using deposit probes
troscopy (ICP-AES) Perkin Elmer Optima 2000 DU and is taken up, as the wide range of characterization of the select-
using Inductively Coupled Plasma-Mass Spectroscopy (ICP- ed limestones with respect to their potential difference as
MS) Perkin Elmer. Sulfation of limestones of different size desulfurisation agents in CFBC boilers yielded no definitive
fractions showed that sorbent requirement (g of sorb/g of sulfur) evidence of the fouling and deposition faced in the operating
is less for finer size fractions [6]. units.
4 Journal of Combustion

Compressed air outlet

Metal temperature measurement

thermocouple

Compressed
air inlet
(a) (b)

(c)

Figure 2: (a) Schematic sketch of probe to collect fouling samples, (b) steel probe with rings [2], and (c) foul probe with deposits.

A deposit probe is a good tool for finding out the mech- 4. Results and Discussions
anisms of deposit formation. Air cooled deposit probes of
type Figure 2 was used for sampling of deposits, which are Analyses of proximate, ultimate, and gross calorific value and
equipped with detachable rings [2]. The temperature of the chemical composition of ashes for the seven lignite samples
probe can be controlled by varying flow rate of pressurized air. are listed in Table 1. Analysis of chemical composition of the
For each test, a new probe/ring is used and the weight of the hold-up material in the cyclone standpipe is furnished in
probe/ring is checked before and after exposure. Taking into Table 2. Detailed limestone analyses-chemical composition,
account exposure time, a rate of deposit buildup (g/(m2 h)) calcium and magnesium carbonate contents for the Indian
can be calculated. Deposited probes/rings are stored for limestones that are used in CFB, are furnished in Table 3.
analysis. Fouling probe test condition/measurement details are fur-
Deposits were collected from three different locations in nished and the chemical composition analysis of the probe
the backpass after SH-1B, in between RH-2 bundles, and after deposits is furnished in Table 4. Mineralogy of the probe
RH-2 (Figure 3). Chemical composition analysis of the probe deposits as determined by XRD is furnished in Table 5.
deposits is carried out. The sieve analysis of deposits shows
significant share of particles smaller than 50 𝜇m size. It was 4.1. Correlation with Conventional Ash Deposition Indices.
clear that addition of limestone significantly increased the Various conventional indices, based upon ash chemistry, have
formation of hard deposits compared to firing only lignite, been calculated as indicators of slagging and fouling propen-
that is, without any limestone. sity [7]. Values for the following indices, for the high sulfur
lignite samples 1 to 7 are given in Table 1:
3.3.2. Particle Size Distribution of Injected Lime. The sieve
Silica ratio = SiO2 /(SiO2 + Fe2 O3 + CaO + MgO)∗100
analysis of collected deposits showed that these deposits were
built up mainly by fine lime particles injected into furnace. Base/acid ratio = (Fe2 O3 + CaO + MgO + Na2 O +
Figure 4 shows distribution of the particle size for two K2 O)/ (SiO2 + Al2 O3 + TiO2 )
samples done by wet sieving. The share of particles smaller
than 50 𝜇m size indicated that fine fractions were higher than Iron index = Fe2 O3 ∗B/A
envisaged during design (0 to 5% less than 50 𝜇m). Earlier Iron/calcium ratio = Fe2 O3 /CaO
researchers have shown that the particle size distribution of
sorbent could significantly affect deposit formation rate [2]. Iron + calcium in ash = Fe2 O3 + CaO
Journal of Combustion 5

Table 1: Proximate, ultimate, chemical composition of ash, ash fusion temperatures, and ash deposition indices of high sulfur lignite.

Sample 6
Sample ID Sample 1 Sample 2 Sample 3 Sample 4 Sample 5
Standpipe blockage
Lignite Giral Lignite Giral Lignite Giral Lignite Giral Lignite Giral
Giral
Proximate analysis (wt % on air dried basis)
Moisture 11.8 10.0 29.6 29.1 15.0 9.6
Volatile matter 37.5 29.5 27.8 28.4 33.7 37.8
Ash 18.6 34.5 15.6 13.9 18.7 26.8
Fixed carbon 32.1 26.0 27.0 28.6 32.6 25.8
Gross calorific value Cal/g 4865 3445 3645 4059 4720 4030
Ultimate (wt % on air dried basis)
Carbon 51.6 38.5 35.3 39.5 49.1 41.0
Hydrogen 3.8 2.5 2.6 2.6 3.3 4.0
Nitrogen 0.6 0.6 0.9 0.8 0.7 0.6
Sulfur 6.94 5.5 4.1 4.7 6.70 4.0
Chemical composition of ash (wt %)
SiO2 25.9 39.2 41.0 36.2 25.1 34.1
Al2 O3 12.6 27.5 22.0 17.7 14.2 14.8
Fe2 O3 28.8 16.5 21.4 25.7 26.4 11.9
TiO2 1.3 2.1 2.3 2.4 1.5 1.6
CaO 8.3 4.2 3.7 5.1 6.6 3.3
MgO 3.3 2.1 2.2 2.2 3.1 1.3
Na2 O 7.2 1.4 1.7 2.8 8.3 4.1
K2 O 0.3 0.6 0.4 0.4 0.3 0.2
SO3 11.0 6.2 5.7 7.2 13.7 28.7
Ash fusion temperatures ∘ C (oxidizing atmosphere)
Temperatures 1 2 3 4 5 6
Deformation T1 >1152 1267 1275 1311 >1152 1244
Softening T2 >1214 1290 1300 1321 >1214 1260
Hemisphere T3 >1230 1307 1333 1364 >1230 >1300
Fusion T4 >1250 1377 1360 1385 >1250 >1300
Ash deposition indices
Si ratio 39.06 63.22 60.02 52.31 41.01 67.4
Base/acid 1.20 0.36 0.45 0.64 1.78 0.41
Iron index 34.56 5.93 9.63 16.45 47.0 4.9
Fe/Ca 3.47 3.93 5.78 5.04 4.0 3.6
Fe + Ca 37.1 20.7 25.1 30.8 33.0 15.2

Table 2: Cyclone outlet standpipe blockage—chemical composition of fuel∗ ash and clinkers.

Material Na2 O MgO Al2 O3 SiO2 SO3 P2 O5 K2 O CaO Fe2 O3 TiO2

Fuel ash—Table 1 sample 6 4.1 1.3 14.8 34.1 28.7 — 0.2 3.3 11.9 1.6
Black clinker 2.6 1.8 3.8 6.4 37.1 0.1 0.1 30.8 16.9 0.4
Brown clinker 2.4 1.6 4.5 7.2 29.7 0.3 0.4 31.5 21.8 0.6
Grey clinker 2.1 1.1 3.6 6.4 35.0 0.3 0.1 31.9 18.9 0.6
∗
Table 1 sample 6.

The interpretation of such ash deposition indices requires of concern and mineral associations, both of which are
caution, as these have been developed for a particular range equally important as the ash chemistry in determination of
or type of coal, and influence of boiler design/operating slagging and fouling. With the above limitations, it can be
conditions is not accounted. Ash chemistry indices do not seen from Table 1 that the values for most of the common
count the mineralogical mode of occurrence of the elements ash deposition indices suggest that the lignite samples would
6 Journal of Combustion

Table 3: Elemental analysis—calcium and magnesium carbonate contents of limestones.

Limestone sample ID (1) SLPP (2) Ariyalur (3) NLC Barsingsar (4) Kutch (5) Giral Rajasthan
Al2 O3 % 4.26 1.72 0.74 2.78 1.98
BaO % 0.02 0.01 0.00 0.00 0.01
CaO % 38.6 48.4 52.1 45.0 47.3
Fe2 O3 T % 12.32 2.27 0.28 1.63 0.79
K2 O % 0.03 0.20 0.04 0.31 0.20
MgO % 0.89 0.35 0.37 1.24 0.71
MnO % 0.34 0.04 0.01 0.03 0.02
Na2 O % 0.02 0.09 0.02 0.21 0.10
P2 O5 % 0.13 0.16 0.07 0.08 0.08
SiO2 % 6.38 4.75 2.05 6.96 6.81
SrO % 0.02 0.01 0.03 0.07 0.03
TiO2 % 0.43 0.08 0.03 0.23 0.10
LOI (900∘ C) 34.4 39.4 41.4 39.4 38.6
CaCO3 g/100 g of stone 70.52 88.67 95.7 82.04 87.30
MgCO3 g/100 g of stone 1.9 0.74 0.8 2.67 1.54

Table 4: Deposit sampling using probes.

(a) Foul probe test conditions—position windward

Rate of Lignite fired during

Test serial Probe temp. Exposure Limestone
Gas temp. ∘ C ∘ SO2 ppm buildup test Giral sample
number C hours tonnes/hr
g/m2 hr numbers (Table 1)
1 685 500 0.5 0 >5000 62 Sample number 2
2 635 500 0.5 0 >5000 34 Sample number 3
3 720 600 0.5 0 >5000 73 Sample number 2
4 680 500 2 5 1800 39 Sample number 3
5 690 500 0.5 8 1800 27 Sample number 4
6 700 500 2 12 1200 61 Sample number 2
(b) Chemical composition of foul probe deposit samples

Serial number Na2 O MgO Al2 O3 SiO2 SO3 K2 O CaO TiO2 MnO Fe2 O3
1 3.3 3.5 12.2 20.5 18 0.3 11.2 2.3 0.1 28.6
2 3.2 2.3 16.2 29.9 8.0 0.4 4.6 1.5 0.2 33.7
3 4.5 3.8 15.9 25.2 15.0 0.4 9.3 2.1 0.2 23.7
4 0.7 1.1 5.1 7.7 36.8 0.0 38.4 0.7 0.0 9.5
5 0.8 0.9 4.1 6.5 39.6 0.0 39.0 0.5 0.0 8.6
6 0.7 0.9 4.8 7.3 37.8 0.1 39.9 0.6 0.0 7.9

have a high propensity to form ash deposits [8, 9]. The Table 5: Ash mineralogy—XRD.
values in bold and italics indicate high propensity for ash
deposition. Agglomeration can start well below the ash fusion Lignite Giral sample 2 Table 1
temperatures in fluidized beds for lignite, and influence of Mineral matter % present
Na2 O (AFT decreases) and Al2 O3 (AFT increases) on Turkish Quartz (SiO2 ) 1.2
lignite was studied by earlier researchers [10]. Anorthite 3.0
Diopside 2.5
4.2. Sulfation of Free Lime in Backpass of Boiler. The inves- Maghemite 3.9
tigations of the deposit hardening phenomenon in the CFB Hematite 10.5
boilers have been widely discussed as the occurrence of three Anhydrite 78.4
types of deposit consolidation mechanisms [11, 12]. Two out
Hexahydrite 0.5
of the three consolidation mechanisms result in increase in
volume of free CaO rich zones in deposits. Fine sorbent Total 100.0
Journal of Combustion 7

Superheater-III

660–720 ∘ C
Superheater-III
Reheater-II

Reheater-II
610–640 ∘ C

Cyclones
2 nos
530–590 ∘ C

Backpass Low temperature SH

Airheater
Combustor
Superheater-IB SH-1B

ESP
FBHE FBHE

ECO.-IV

ECO.-III

ECO.-II

ECO.-I

Figure 3: General arrangement of CFBC boiler and backpass.

Rajasthan-Giral lime of particles are already calcined before entering the second
100 1000 pass of the boiler. During their residence on tube surfaces in
710 the convective section, these particles undergo a continuous
90 500 sulfation through an exothermic reaction (1). The sulfation
80 355 process is described by the following overall reaction [2]:

70 212
1
CaO + SO2 + O2 󳨀→ CaSO4 + 481 kg/mol (1)
60 125 2
Passing (%)

75
50
Further if the temperature of flue gas in vicinity of the sorbent
20 32 45
40 particle is sufficiently high, then the local temperature of the
deposits is likely to exceed the sintering temperature due to
30 exothermic reaction and hence, as a result, the agglomeration
could occur.
20
It had been shown by earlier researchers that the agglom-
10 eration can occur between 750 and 950∘ C via the second
mechanism, the extended sulfation process [12]. The temper-
0 ature for optimum sulfur capture is about 850∘ C [13]. The issue
10 100 1000
to be understood is whether there exists an optimum temper-
(𝜇m)
ature range for extended sulfation (long term) [14]. Sulfation
Test 1 appears to be the dominant agglomeration mechanism in
Test 2 systems that use high sulfur fuel with calcium-based sorbents
Figure 4: Shares of particles smaller than 50 𝜇m in limestone sam- for low ash fuels like pet-coke [15]. The deposits are shown
ples. to be composed predominantly of CaSO4 and in some cases
almost pure CaSO4 [16, 17]. Low temperature (down to
750∘ C), agglomeration mechanism may be via carbonation
particles, settled either on the tube surface or in the caverns and then sulfation [18].
on the “rough” surface of the old deposits, (Figure 5) are Herein the fuel used is lignite having ash content ranging
exposed to SO2 -containing flue gases. These sorbent particles from 15 to 35% and the gas temperature range where the
are fine (i.e., not captured in the cyclone), and the majority deposits occurred is from 600∘ 𝐶 to 720∘ 𝐶.
8 Journal of Combustion

Macropores
Sulfated lime
Micropores
Unreacted lime
−CO2 + SO2 + 1/2 O2

CaCO3 CaO CaSO4

CaO + CO2 + 1/2 O2 ⇔CaCO3 Flue gas temp based <750 ∘ C recarbonation

CaCO3 + SO2 ⇒CaSO4 + CO2 Extended sulphation >750 ∘ C causing hard deposits

Figure 5: Consolidation mechanisms—sulfation of free lime.

In CFBC, sulfation is followed by carbonation of CaO and With no limestone addition, the flue gas was estimated
these reactions can be represented as follows [11]: to contain around 6,900 ppm SO2 (with 6.1% sulfur in fuel
and 3% O2 in flue gases). With 12 t/h limestone addition, the
CaCO3 󳨀→ CaO + CO2 (calcination) (2) corresponding emissions measured were 1400 ppm SO2 . The
tests were conducted at site to study reactions of lime particles
CaO + CO2 󳨀→ CaCO3 (recarbonation) (3)
in flue gas to understand the formation of deposits containing
1 various calcium compounds. The boiler load was varied by
CaCO3 + SO2 + O2 󳨀→ CaSO4 + CO2 increasing the lignite feed and corresponding increase in the
2 (4) limestone to control the SO𝑥 level. The very fine limestone
(extended sulfation) particles were calcined, and less than 50-micron level escaped
out of the cyclone to backpass and settled over the superheater
Carbonation mechanism dominates between temperature and reheater coils. As seen in Table 4 chemical composition
range of 650 and 790∘ C at typical CO2 partial pressures analysis indicates that adding limestone changes the whole
(15 kPa) in a CFB boiler, which is much faster than sulfation chemistry of the deposits mainly from silicon-aluminum-iron-
and is then followed by sulfation of the deposit. based deposits (samples 1 to 3) to calcium-based deposit
A third possible mechanism thought to cause agglomer- (samples 4 to 6). The calcium compounds present are mainly
ation is hydration followed by carbonation [12]. This type of CaO, CaCO3 , and CaSO4 as seen in XRD (Table 5).
fouling is not common in FBCs because they are normally
operated at temperatures well above at which Ca(OH)2 is sta- The root cause of the fouling problem is carbonation
ble under atmospheric conditions (≤450∘ C). The hydration and then sulfation reactions of the limestone particles. Loose
reaction may be represented by the following equation: limestone particles deposit sinter on surfaces and form hard
deposits, particularly in flue gas temperature range around
CaO + H2 O ←→ Ca(OH)2 (5) 500–700∘ C. As explained earlier, it can be safely concluded,
at Rajasthan-Giral, that recarbonation reaction is dominant
This must be followed by carbonation at temperatures below in range of 650–750∘ 𝐶 and the extended sulfation reaction
450∘ C via the following reaction: (dominant in range of 750–850∘ 𝐶) leads to hardened deposits.
Ca(OH)2 + CO2 ←→ CaCO3 + H2 O (6) Ash formed, due to combustion of high sulfur lignite,
does not form (sticky or sintering) deposits without lime-
Traditional fouling mechanism due to presence of elements stone addition. These hard deposits were formed due to
that are associated with ash softening or melting, in particular fine calcined limestone particles (<50 𝜇m) that leave the
K, Na, and V, is not applicable for the fuels studied due to low cyclone. These particles settle on the superheater surfaces
levels of Na, K, and V present [19]. and react with CO2 between 650 and 750∘ C leading to
recarbonation and then with SO2 between 750 and 850∘ C
4.3. Detailed Analysis of Ash Forming Matter in the Giral Lig- furthering extended sulfation, forming sintered and hard
nite. Giral lignite has high ash content, 15 to 35% (Table 1), deposits (Figure 6). The hypothesis is that in CFBC, carbon-
which makes it unique, with respect to quantum of ash and ation takes place as a dominant reaction forming calcium
the rate at which it was deposited at the backpass. The prin- carbonate (at temperature range of 650 to 790∘ C) and then
cipal ash forming elements that play significant role in the extended sulfation takes place between 750∘ C and 850∘ C. The
fireside problems of the boiler, as indicated by mineralogy environment of flue gas and exothermic reactions contributes
of the lignite (determined by XRD), are aluminum silicate to the conversion of the deposits already formed as calcium
(kaolinite minerals) and iron compounds (pyrite, FeS2 ). carbonate into calcium sulfate. The particles settle as deposits
Journal of Combustion 9

Flue gas temperature profile

44
42
40
38 SH3
36
Backpass height (m)

34

Recarbonation
32 RH2
Sulphation

30
extended sulphation
Recarbonation with
28
26
24 SH1B
22
20
18 Economiser
16
14
12
10 (a)
950 900 850 800 750 700 650 600 550 500 450 400 350 300 250
∘
Flue gas temperature ( C)

Figure 6: Recarbonation and extended sulfation range and location.

on the tube surface, continue their reaction journey and form

as calcium sulfate.

4.4. Optical Microscopy. Optical microscopy of the deposit

samples shows a layered structure (Figure 7) defined mainly
by mineralogical variation, principally in anhydrite (CaSO4 )
and iron oxides. Giral ashes are unusual in the occurrence (b)
of complete sulfation of the decarbonated limestone with
Figure 7: (a) Photomicrograph of superheater deposit. Reflected
no evidence of either the occurrence of intermediate phases
light images showing curvilinear layering. (b) Photomicrograph of
such as calcium oxide or the presence of sulfate reaction anhydrite CaSO4 /iron oxide Fe2 O3 layer—in transmitted polarised
rims (Figure 5) on decarbonated limestone [16, 17]. Reason light-white anhydrite and dark brown iron oxide grains.
for this unusual behavior is the high sulfur content of the
Giral lignite which might have resulted in complete sulfation
of the limestone. Additional factor is the greater proportion
of fine particles in the milled Giral limestone which would
react completely [6]. This observation is supported by the
occurrence of fine anhydrite particles in the Giral backpass
sample and a subsequent increase in grain size in the back end
of the boiler, suggesting that winnowing of the fine particles
has occurred in the hotter sections of the backpass.

5. Field Trials/Modifications and

Improvement Carried out
5.1. Standpipe Blockage. The chemical compositions of
the lignite (Table 1), cyclone ash (Table 2), and limestone
(Table 3) were analyzed. During commissioning, cyclone (a)
standpipe choking due to clinkers (Figure 8) with low com-
bustor temperature of less than 750∘ C was noticed. The
analysis reveals that the composition does not vary much
and contains mostly calcium oxide (CaO). The phenomenon
of recarbonation of calcined limestone (CaO + CO2 →
CaCO3 ) unreacted with sulphur dioxide was suspected, as a
root cause for loose bonding of material at cyclone standpipe
leading to blockage of cyclone [20]. This is reflected in the
cyclone ash analysis by the presence of free lime (Table 2).
The following steps were taken: (a) limestone feed size
was checked with more sampling; (b) excessive limestone
feed rate was reduced; (c) the operation procedure was (b)
revised to maintain higher combustor temperature before
starting limestone addition; and (d) automatic pincing air Figure 8: Cyclone outlet standpipe clinkers.
10 Journal of Combustion

Equilibrium of free calcium oxide in CFB environment Exhaust

20
17.5 Bag Bag Bag
Vol of CO2 (%)

15 CaCo3 is more stable filter-1 filter-2 filter-3

12.5
10 Use of limestone to Suction fan
be carefully regulated Typical CFB operating regime
7.5 in this zone.
RAL
5
2.5
CaO is more stable Screw feeder-2
0
500 540 580 620 660 700 740 780 820 860 900 940
Screw feeder-3
Operating temperature (∘ C) Proposed
line
Vol of CO2 Side gate
valve BIN-1
Nb 150 line
Figure 9: Recarbonation-prone regime for limestone addition. Slide gate
valve
Truck

arrangements at junction of the cyclone and standpipe to

disturb the agglomeration were incorporated. Figure 10: Lime mill arrangement for segregation of lime powder
After incorporation of changes in operation procedure particles less than 50 microns.
and with pincing air arrangements, the issue was resolved.
The timing of pincing was reduced by maintaining temper-
ature above regime of recarbonation at the cyclone stand- Screen
pipe. Figure 9 shows specific recommendations for avoiding,
recarbonation-prone regime for limestone addition [20]. The Existing hopper
curve denotes the limit of equilibrium of calcium com-
pounds. As shown in the equilibrium diagram (Figure 8), Fluidising pad
CaCO3 is stable on the left side of the line, whereas CaO is
stable on the right side. In the field, CaO was found abundant Extended hopper
because of excess limestone added to the furnace. When the Plant air for
Isolation gate fluidisation
temperature was reduced to recarbonation range, sticky car-
bonate causing agglomeration blocked (Figure 8) the cyclone Discharge chute
standpipe.

5.2. High Pressure Soot Blowing. High pressure soot blowing

was introduced in the final superheater (FSH), and reheater
(RH) and in low temperature superheater (LTSH). After
increase in soot blowing pressure from 10 to 20 kg/cm2 g,
deposits were completely eliminated. Deposits could be
removed easily, nearer to the soot blower location, and Figure 11: Modified arrangement of economizer hopper for removal
deposits located away from lance, accumulated proportional of bigger particles.
to distance from soot blower. Because continuous soot
blowing was needed to keep the boiler surfaces clean, addi-
tional soot blowers were introduced at selected locations as fluidizing pad at the discharge end and increase in diameter
shown in Figure 1, and deposits were eliminated completely of discharge chute. A screen is provided inside hopper, close
(Figure 1). to the outlet chute, to separate ash particles below 6 mm into
the ash evacuation system (Figure 11).
5.3. Limestone Size Distribution. Lignite without limestone
addition caused little or no hard deposit buildup in the back- 6. Conclusions
pass of CFB boiler. The severity of the fouling (hard deposits)
was clearly dependent on the amount of limestone addition. Sorbent limestone is used widely in CFB boilers effectively to
Deposits contained very small fines of less than 50 𝜇m size control sulfur dioxide emissions. Hard deposits were formed
fractions. It was found that 30–40% of the feed limestone was in backpass of CFB boiler while using high sulfur Indian
smaller than 50 𝜇m (Figure 4). Both dry and wet sieving tests lignite and limestone sorbent to control SO2 . In addition
indicated fine fractions were higher than envisaged during large quantum of loose deposits caused severe blocking of the
design. (0 to 5% less than 50 𝜇m). Excess quantity of fines second pass. Unreacted calcium oxides that settled on heat
<50 𝜇m generated in the milling process was removed by transfer tubes at temperature between 650∘ C and 750∘ C were
providing a separate elimination line (Figure 10). In addition, subjected to recarbonation and further extended sulfation
the deashing arrangement was improved by introduction of which resulted in the hard deposits. Elimination of fines,
Journal of Combustion 11

less than 50 𝜇m, in feed limestone could effectively reduce [2] R. Kobyłecki, S. Gołąb, L. Krzemień, J. Tchórz, and Z.
the hard deposits formation in backpass of CFB boiler. This BisCzęstochowa, “Fouling in the back pass of a large scale
confirms the finding of the previous studies carried out at CFBC,” in Proceedings of the 9th International Conference on Cir-
other institutions firing high sulfur but low ash fuels. Rate of culating Fluidized Beds, 2008.
buildup of deposit and chemistry of deposits in backpass of [3] S. V. Pisupati and A. W. Scaroni, “Sorbent characterizataion for
CFB boiler were studied using special foul probes. The rate FBC application,” in Proceedings of the 10th Annual Fluidized
of buildup of deposit was proportional to the increase in ash Bed Conference, 1994.
content of lignite and sorbent feed rate. Solution to control the [4] M. Fabio, S. Piero, S. Fabrizio, and U. Massimo, Sulfur uptake
fouling in 125 MWe CFB boiler is to minimize the amount of by Limestone based sorbent particles in CFBC: the influence of
free lime particles (CaO) in the system formed due to excess attrition / fragmentation on sorbent inventory and particle size
distribution-CFB 10, 2011.
addition of fines in feed limestone (less than 50 𝜇m). The fine
fractions of limestone feed <50 𝜇m coming out of milling [5] M. Olas and R. Kobyłecki, BisZ—Simultaneous calcination and
sulfation of limestone based sorbents in CFBC-effect of
circuit were removed by providing an elimination line.
mechanical activation-CFB 9, 2009.
Other CFB boiler operational issues faced, namely,
[6] S. J. Hari and V. P. Sarma, A Study on Indian Limestones For Sul-
cyclone standpipe blockage, cleaning the heat transfer sur-
fur Capture-The EMS Energy Institute and John and Willie Leone
faces deposited with huge quantum of loose ash, and ash Department of Energy Mineral Engineering, The Pennsylvania
evacuation to separate the large size deposits/particles, were State University, 2012.
effectively resolved through introduction of pincing air [7] Common slagging and fouling indices, http://www.coaltech
at the junction of cyclone and standpipe, high pressure .com.au/LinkedDocuments/Slagging&Fouling.pdf.
(20 kg/cm2 g) soot blowing in selected locations, and incor- [8] Rod Hatt, Coal Combustion, Inc.Correlating the slagging of
poration of fluidizing pads and screens in ash hoppers, a utility boiler with coal characteristics-http://65.163.62.71/
respectively. PDF%20Files/Corre Slag efc3.pdf.
Frequent soot blowing and provision of soot blowers at [9] R. C. Attig and A. F. Duzy, “Coal ash deposition studies and
additional locations were effective in clearing the huge quan- application to boiler design,” Proceedings of American Power
tum of loose deposits. Conference, vol. 31, pp. 290–300, 1969.
[10] H. Atakül, B. Hilmioǧlu, and E. Ekinci, “The relationship
Abbreviations between the tendency of lignites to agglomerate and their fusion
characteristics in a fluidized bed combustor,” Fuel Processing
AFT: Ash fusion temperature Technology, vol. 86, no. 12-13, pp. 1369–1383, 2005.
ASTM: American Society for Testing Materials [11] E. J. Anthony, A. P. Iribarne, J. V. Iribarne, R. Talbot, L. Jia, and
Al2 O3 : Aluminum oxide D. L. Granatstein, “Fouling in a 160 MWe FBC boiler firing coal
CaCO3 : Calcium carbonate and petroleum coke,” Fuel, vol. 80, no. 7, pp. 1009–1014, 2001.
CaO: Calcium oxide [12] E. J. Anthony, R. E. Talbot, L. Jia, and D. L. Granatstein,
CaSO4 : Calcium sulfate “Agglomeration and fouling in three industrial petroleum coke-
CFBC: Circulating fluidized bed combustion fired CFBC boilers due to carbonation and sulfation,” Energy
GDP: Gross domestic product and Fuels, vol. 14, no. 5, pp. 1021–1027, 2000.
LTSH: Low temperature superheater [13] P. F. B. Hansen, K. Dam-Johansen, L. H. Bank, and K. Oster-
LRSB: Long retract soot blower gaard, “Sulphur retention on limestone under fluidized bed
MWe: Mega Watt electrical combustion conditions. An experimental study,” in Proceedings
of the 11th International Conference on Fluidized Bed Combus-
RH: Reheater
tion, pp. 73–82, April 1991.
SH: Superheater
[14] E. J. Anthony and D. L. Granatstein, “Sulfation phenomena in
SiO2 : Silicon dioxide
fluidized bed combustion systems,” Progress in Energy and Com-
SO2 : Sulfur dioxide bustion Science, vol. 27, no. 2, pp. 215–236, 2001.
TGA: Thermogravimetric analysis
[15] E. J. Anthony, A. P. Iribarne, and J. V. Iribarne, “A new mecha-
XRD: X-ray diffraction. nism for FBC agglomeration and fouling in 100 percent firing
of petroleum coke,” Journal of Energy Resources Technology,
Acknowledgment Transactions of the ASME, vol. 119, no. 1, pp. 55–61, 1997.
[16] E. J. Anthony, A. P. Iribarne, and J. V. Iribarne, “Fouling in
The authors thank the Management of BHEL for the oppor- a utility-scale CFBC boiler firing 100% petroleum coke,” Fuel
tunity to present their views through this paper on this Processing Technology, vol. 88, no. 6, pp. 535–547, 2007.
important topic. The views expressed in this paper are those [17] E. J. Anthony, L. Jia, and K. Laursen, “Strength development due
of the authors and not necessarily those of BHEL. to long term sulfation and carbonation/sulfation phenomena,”
Canadian Journal of Chemical Engineering, vol. 79, no. 3, pp.
356–366, 2001.
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[18] E. J. Anthony and L. Jia, “Agglomeration and strength develop-
[1] A. Lawrence, V. Ilayaperumal, K. P. Dhandapani, S. V. Srini- ment of deposits in CFBC boilers firing high-sulfur fuels,” Fuel,
vasan, M. Muthukrishnan, and S. Sundarrajan, “A novel tech- vol. 79, no. 15, pp. 1933–1942, 2000.
nique for characterizing sintering propensity of low rank fuels [19] E. J. Anthony, F. Preto, L. Jia, and J. V. Iribarne, “Agglomeration
for CFBC boilers,” Fuel, vol. 109, pp. 211–216, 2013. and fouling in petroleum coke-fired FBC boilers,” Journal of
12 Journal of Combustion

Energy Resources Technology, Transactions of the ASME, vol. 120,

no. 4, pp. 285–292, 1998.
[20] M. Lakshminarasimhan, B. Ravikumar, A. Lawrence, and M.
Muthukrishnan, High Sulfur Lignite Fired Large CFB Boilers:
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