Uninterrupted and Reliable Operation For CFB BOILER

Uninterrupted and Reliable Operation For CFB Boiler
BEIJING DATONGLONGYUAN ENERGY TECHNOLOGY Co.,LTD
PT DATONG JAYA INDONESIA

www.datonglongyuan.com
Mr.Andy Wan
0086 - 13910117983
0062- 81297753376
[email protected]
Uninterrupted and reliable run for CFB Boiler
Circulating Fluidizing Bed Boiler ( CFB) is a proven clean energy

harness technology , it suits a variety of fossil coal , well running
characteristics , environmental friendly . It has been developing
rapidly domestic and abroad . With application of CFB BOILER de-
sulfurization can be obtained inside furnace . Nox emission
reduced to 1/3 – 1/4 of PC Boiler . Comparing with PC boiler , CFB
boiler develops fast , naturally, some issues come up need to be
justified and address , some issues existing observed after boiler
put into run , some run are not so well , give CFB boiler technology
bad reputation . On top of that , comparing with PC boiler,
Uninterrupted and reliable run for CFB Boiler
uninterrupted run of a CFB boiler is critical indicator . How to avoid unscheduled

outage is everybody’s concern.
As matter of fact , there are lots of factors impact CFB boiler’s reliability .
As per our long time research and modification experience, we found out , 3 key
aspects are affecting CFB boiler uninterrupted run .
1. Reliable performance of coal handling system ensure undisruptive coal

feeding .
2. Anti-abrasion measures taken on key eroded areas reliable, reduce risk of tube
rupture .
3. Slag cooler stable and reliable performance ensure smooth slag discharge .
CFB Boiler Uninterrupted Run Indicators Analysis
Unschedul ed Out age

2014 National Benchmark for CFB Boiler
Plants 300MW Capacity , mean
unscheduled outage 0.33/unit.year
Some units 300MW Capacity obtained
record high uninterrupted run days .
• Availability Hour s
Unit #5 , Baolihua Plant : 434 days .
200MW Capacity , Shenhua Yili Plant Unit
#1 : 341 days .
135MW Capacity , Pansan Plant Unit #1 :
311days .
Anti-clogging Technology for Coal Handling System
Coal Feeding System Clogging Caused Coal Supply Interruption
1. Raw coal bunker clogging impacts unit output load .

In case clogging emerges , coal feeder normal runs interrupted ,coal
supply decreased , likely the unit is forced to ramp down .
2. Pose threat to Unit safety run .

In case clogging occurs, coal feeder normal affected , triggers boiler
unstable combustion . In case multiple coal feeder coal supply
interrupted ,Boiler steam generation drops in large scale , combustion
gets worse , likely fire out causing unscheduled shutdown . On top of
that ,sometimes , in case coal feeder encounters coal interruption,
likely flue gas goes reverse into CF ,cause unimagined incident .
3. Raw coal bunker clogging impacts economical run

In case coal bunker clogging emerged , plus interrupted coal
feeder work , in light of stabilizing combustion , alternatively ,
fuel oil is applied , thus, operational cost increased .
Therefore , clogging affects unit normal run , clogging prevention

shall have to be put on emphasis in normal operation, ensuring safety ,
economical and civilized production .
头疼的原煤仓
Traditional Solution
Our Unique Solutions
Generally speaking ,clogging occurred
at position 3m above coal feeder inlet,
ie, the area coal bunker’s diameter
smaller than 1500mm , mainly due to
coal accumulating at this point
because of gravity , plus , flowing
passage getting narrower, coal caking
emerged ,interrupts normal coal
flowing . As per our long time expertise
, if only we are capable of ensuring
this troubled portion coal flow
smoothly , meaning to say , normal
coal flows not being interrupted . A
rotation-knife-scraper applied to
remove caked coal , allows incoming
coal falling freely wide open passage .
Our Unique Solutions
Our solutions :Application of rotation – knife-scraper both above and
below slide – gate – valve , the latter placed just above coal feeder
inlet port 100mm, guarantee there is no dead zone spared for
uninterrupted coal flow .
Typical Applications
Indonesia Sumatra Power Plant Application
Working Principle of Rotation-knife Scraper
The device is driven by actuator via gear box , the rotation – knife-
scraper is turning to remove coal adheres to inner surface of coal bunker
, ensuring uninterrupted coal flow .
Unique Workmanship of Slide-gate-valve
Comparing with traditional Slide –gate-valve , there is no chance of coal
accumulating inside our improved product .
Our improved product made of stainless steel overall .
Anti-accumulating provision designed , avoid occurrence of deformation due
repeat operation, results failing to open & close fully .
Working Principle of Rotation-knife Scraper
Rotation-knife-scraper installed below Slide-gate-valve enable

absolute removal sticky coal with uninterrupted flow, it locates
100mm above conveyer belt ,coal falls onto and delivered to furnace
through coal dropping chute .
control system
Three control modes designed :
1、local control： provide
operation on the spot。
2、DCS control：provide remote

control。
3、Sequence control:
Two control modes，one is
controlled by coal feeding
flow, when coal flow is less
than setting value, it starts
automatically. In case coal
flow resumes to normal, it
stops。Another mode is 《Control Pannel》
timing。
Application in Newly Built Power Plant
Before and After Modification
Before and after Modification
Coal Chute Clogging Solution
Note : Animation video available for demonstration .

Anti-abrasion Comprehensive Modification Inside Furnace
Anti - Abrasion Measures

for Key Easy Abrasion Areas
Anti-abrasion Comprehensive Modification Inside Furnace
In the course of CFB Boiler application , acknowledge abrasion principle on
metal surface and fair assessment of abrasion rate , will play significant role
in aspects of Boiler design and routine O & M .
In a certain extent, the economy and availability for A CFB Boiler subjects to
its anti-abrasion design and abrasion-proof performance.
 Double abrasion
 Triple abrasion
Abrasion Rate
wxf
CFB Boiler Key Eroded Area
Water wall surrounding tubes
Dense area refractory
Overlapping between dense area
and water wall
Furnace four corners
Furnace flue gas exit access
Furnace middle portion
Platen through water wall
 Furnace Platen lower part
Distribution plate and air nozzle
 Furnace ceiling area
 Separator incoming and discharge
 duct
 Loop seal vertical chute and inside
Heat reheat area
Abrasion at Refractory Overlapping Area
Abrasion at Refractory Overlapping Area
Side water wall
Refractory Material
Abrasion observed At Dense Area
Coal feeding Port

Water wall At Furnace Corner
Abrasion Observed at Water wall At Furnace Four Corners
abrasion caused by Inappropriate

refractory workmanship
Abrasion Observed at Water wall At Furnace Four Corner
Flue gas flush shall have to be

considered during installtion.
Abrasion Observed at Water Wall Dilute Area
Tube Burst due to

Water Wall Partial Water Wall Finned Plate
Inappropriate Structure abrasion
Water Wall abrasion at Dilute Area
Weld seam not properly polished
cause abrasion
Finned plate deformed cause

abrasion
Water Wall abrasion at Cyclone Separator
Water Wall abrasion at Cyclone Separator
abrasion caused by Flue Gas entry Cyclone Separator

Abrasion on Platen Heat Exchanger
Eroded on Extended Platen Eroded on Double Water Wall

Collector Through Water wall
Abrasion Caused by Platen Deformation
Platen Re heater Platen Re heater Tube

Deformed ( 150MW) Eroded and Burst(135MW)
Abrasion at Platen Area
Refractory Material Detached due to

Platen Re-heater deformed
Abrasion due to Platen Refractory Material Detached
Platen Heating Surface Layout and Anti-abrasion Design
Height maintains 15m above
Air Distribution Plate.
 Span between two platens
greater than 700mm, thus,
remain ample spacing for
maintenance purposes .
 Anchor pin :1000Pieces/m2 is
recommended .
 Good quality cast able plastic
refractory applies.
Sealing and Expansion Design
Expansion differential shall have to consider between Platen and water wall seal .
Expansion bellow required , both expansion and seal to be considered .
Metal expansion bellow shall be suppressed prior installation .
External Bed
Low fluidizing velocity selection during design . ( 0.5m/s , theoretically

abrasion far and away less.
• Imported 300MW CFB Boiler ,tube burst occurs due to tube bundle clipping
zone impacting .
• Detailed design shall consider – resolving expansion and vibration issues .
Air Nozzle abrasion
 Internal leaks.
 Air resistance poor Match
up.
 Short lifespan, easy eroded .
Air Nozzle abrasion Issues
 Inner labyrinth design
 Avoid Ash Seeping into distribution plate .
 High Withstanding abrasion .
 Resistance characteristic remain unchanged ,

outer smaller hole velocity adopted .
 Replacement not need for a Overhaul interval .

Special Spay Lining Technology
 Ultrasonic Spray
 Arc Spray
 Special Spray Alloy material enhanced water wall anti-abrasion

capability , prolong lifespan.
 In particular , for those Boiler burning good quality coal , evidently
prolongs lifespan after Special Spray done .
Precautions for Special Spay Modification
Those Boiler burned inferior coal , ( LHV and High ash content ) special
spray protection cycle short , under different cases , approximate 3 – 12
months .
• Special Spay service providers varies a lot , as implementation
requirements is strict , sometimes , wrinkles or uneven emerged , de-scale
or detached readily , becomes new vulnerable position for burst .
• Welding seam ruined , spray material penetrates into base material ,
resulting water wall tube rupture . Secondary handling takes time ,
involving more workload . As you know , shut Boiler down , necessary
polish and rinse , buildup and double spray taken .
Special Lining Applications
Lining Overlapping Lining De-scale

Issues Observed after Special Lining
Water Wall Eroded due to Buildup After Burst and Redo

Partial Lining Detached Lining
Positive Multiple Elevations Anti-abrasion Beam Technology
 Anti-abrasion convex formed by refractory material , along water wall
height , lay out at set interval or incline multiple elevations .
 Anti-abrasion convex evidently slowdown ash dripping velocity and
density ( velocity drops from 8m/s to 2m/s .)
 Guarantee water wall lifespan prolongs from approximate 3 months to
over 1 year .
Technical Hallmarks
1. Positive Approach, ease ash dripping velocity and density .
2. Easy installation, large modification inside furnace not necessary .
3. Reliable performance, maintenance free.
Positive Multiple Elevations Anti-abrasion Beam Technology
Positive Multiple Stage Anti-abrasion Beam Technology
Prior After
Modification Modification
Snapshot of Applications
Statistics Analysis after Modification
 Ruiping Power Plant , Henan, CFB Boiler ,
2*135MW , coal feeding LHV 3600kCal/kg , ash

content as received 45 %.
 Anti – abrasion beams were installed during
Boiler installation （Special spray not applied.）
 Unit #2 : unscheduled outage not occur due to
water wall tube burst because of abrasion since
put it into commercial run , till Sep.7 , 2010 ,
runs over 20000 hours .

Statistics Analysis After Modification
Water wall tube thinning 90% of measuring points ≤ 0.2mm ,
Middle wall 70% ≤ 0.2mm . Platen Super heater 80% of ≤
0.2mm, Platen re-heater thinning for all points ≤ 0.2mm .
Application List
 Ruiping Power Plant , Henan (2×135MW CFB Boiler )
 Chentang Power Plant TianJin (1×135MW CFB Boiler)
 Zhongfu Power Plang , Henan (1×135MW CFB Boiler )
 Hua dian Uda Power Plant (2×150MW CFB Boiler )
 QinHuangdao Power Plant (2×300MW CFB Boiler )
 Guodian Xiaolongtan Power Plant (2×300MW CFB Boiler )
 ShenHua Xilaifeng Power Plant (2×200MW CFB Boiler )
 Linhuan Zhongli Power Plant, Anhui (2×300MW CFB Boiler)
 Baolihua Power Generation Company , Canton (1×300MW CFB Boiler)
 Xuzhou Mining Power Generation Company (2×300MW CFB Boiler)
 Pingshi Power Generation Company Shaoguan (2×300MW CFB Boiler)
 Datang Honghe Power Plant (2×300MW CFB Boiler )
Summary
Main factors of resulting furnace water wall abrasion : ash dripping along
tube bundle.
 From aspects of design and Boiler selection , consideration of applicable
cross section flue gas velocity regards key of alleviating furnace abrasion .
 From aspect of engineering methodology , improve erection workmanship
is insurance of lessening abrasion on Water wall .
 Application of Anti – abrasion Beam , Give-in Tube and Special Spray can
reduce water wall abrasion .
 Application of Anti-abrasion Beam obtained significant outcome in aspect
of Boiler abrasion prevention .
BEIJING DATONGLONGYUAN ENERGY TECHNOLOGY Co.,LTD
PT DATONG JAYA INDONESIA

Uninterrupted and Reliable Operation For CFB BOILER

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Uninterrupted and Reliable Operation For CFB Boiler

BEIJING DATONGLONGYUAN ENERGY TECHNOLOGY Co.,LTD

PT DATONG JAYA INDONESIA

Circulating Fluidizing Bed Boiler ( CFB) is a proven clean energy

uninterrupted run of a CFB boiler is critical indicator . How to avoid unscheduled

1. Reliable performance of coal handling system ensure undisruptive coal

Unschedul ed Out age

1. Raw coal bunker clogging impacts unit output load .

2. Pose threat to Unit safety run .

3. Raw coal bunker clogging impacts economical run

Therefore , clogging affects unit normal run , clogging prevention

Rotation-knife-scraper installed below Slide-gate-valve enable

2、DCS control：provide remote

Note : Animation video available for demonstration .

Anti - Abrasion Measures

Side water wall

Coal feeding Port

abrasion caused by Inappropriate

Flue gas flush shall have to be

Tube Burst due to

Finned plate deformed cause

abrasion caused by Flue Gas entry Cyclone Separator

Eroded on Extended Platen Eroded on Double Water Wall

Platen Re heater Platen Re heater Tube

Refractory Material Detached due to

Low fluidizing velocity selection during design . ( 0.5m/s , theoretically

 Avoid Ash Seeping into distribution plate .

 High Withstanding abrasion .

 Resistance characteristic remain unchanged ,

 Replacement not need for a Overhaul interval .

 Special Spray Alloy material enhanced water wall anti-abrasion

Lining Overlapping Lining De-scale

Water Wall Eroded due to Buildup After Burst and Redo

2*135MW , coal feeding LHV 3600kCal/kg , ash

 Anti – abrasion beams were installed during

Boiler installation （Special spray not applied.）

 Unit #2 : unscheduled outage not occur due to

water wall tube burst because of abrasion since

put it into commercial run , till Sep.7 , 2010 ,

runs over 20000 hours .

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