Presentation on CFBC Boilers

Welcome
to
Presentation
on
CFBC Boilers

Bharat Heavy Electricals Limited TIRUCHIRAPALLI FBC & HRSG

 Presentation on CFBC Boilers
CFBC Development Journey
• Test Facility installed – 1991
• Collaboration with LLB ( LEE ) – 1993
• Technology transfer/Training of Engineers - 1996
• First non –reheat boiler (175 t/h ) installed at BILT , Bhigwan - 1998
• First Utility reheat boiler ( 2x125 MW ) installed at SLPP , Mangrol - 1999
• Testing of Lignite – 2001
• 125 MW order received from RVUNL, Giral – 2003
• 75 MW order received from GEB, Kutch – 2004
• 2 x 135 t/h order received from M/s Gujarat Ambuja cement - 2004
• 2 x 250 MW order received from Neyveli Lignite Corporation – 2005
• 125 MW repeat order received from RVUNL, Giral – 2005
• 2 x 125 MW order received from NLC – Barsingsar firing Rajasthan Lignite–
Oct 2005
• 2 x 125 MW repeat order received from SLPP – March 2006
Bharat Heavy Electricals Limited TIRUCHIRAPALLI FBC & HRSG
 Presentation on CFBC Boilers
Basic Flow Diagram of CFBC Boiler

SECONDARY
AIR

ID Fan

Bharat Heavy Electricals Limited TIRUCHIRAPALLI FBC & HRSG

 Presentation on CFBC Boilers
Advantages of CFBC
 Simplified Fuel Preparation and feeding (No Pulveriser)
 In-Situ SOx and NOx control
 Oil support for load below 30% and start up only
 Slag-Free Combustion. Dry ash powder only
 FSSS avoided. Burner Management for Start-Up Burner
only
 Lower Temperature / Less Intense (no flame)
Combustor Environment
 Suitable for using wide range of fuels in the same boiler
 Suitable for fuels which are difficult to burn
 High Carbon Burn-out (Very low carbon in ash)

Bharat Heavy Electricals Limited TIRUCHIRAPALLI FBC & HRSG

 Presentation on CFBC Boilers

Why Fluid Bed Combustion ?

Bharat Heavy Electricals Limited TIRUCHIRAPALLI FBC & HRSG

 Presentation on CFBC Boilers

SOx Control

• Sulphur in fuel captured in combustor by

addition of limestone

• Ca/S Molar Ratio varies between 1.5 to 2.5

depending on the Limestone Quality

• Expensive (FGD) add-on equipment avoided.

Reliability improved

Bharat Heavy Electricals Limited TIRUCHIRAPALLI FBC & HRSG

 Presentation on CFBC Boilers

SO2 Control Reactions

• Straightforward method - Limestone addition

along with fuel into combustor

• Reactions

S + O2 SO2

CaCO3 CaO + CO2 (Calcination)

CaO + SO2 + 1/2 O2 CaSO4 (Sulphation)

Bharat Heavy Electricals Limited TIRUCHIRAPALLI FBC & HRSG
 Presentation on CFBC Boilers

Limestone Requirement
Limestone Requirement

Temperature
Bharat Heavy Electricals Limited TIRUCHIRAPALLI FBC & HRSG
 Presentation on CFBC Boilers
Formation of NOx and Control
• NOx formation
 Thermal NOx - Nitrogen in Air
 Fuel NOx - Nitrogen in Fuel

• Thermal NOx depends on Combustion temperature

In FBC boilers, the Combustion temperature is around
850°C, hence Thermal NOx is negligible

• Fuel NOx depends on excess air levels & Staging

In addition to low excess air levels, the combustion air is
staged. Hence Fuel NOx is also low

Bharat Heavy Electricals Limited TIRUCHIRAPALLI FBC & HRSG

 Presentation on CFBC Boilers
Advantages of FBHE

Spiess
Valve

Bharat Heavy Electricals Limited TIRUCHIRAPALLI FBC & HRSG

 Presentation on CFBC Boilers
Distinct Advantages of FBHE

❁ Elimination of heat transfer bundle / panel in combustor

❁ Very Low carbon in ash and Limestone consumption even

at part load due to Optimum combustor temperature
(about 850 Deg C )

❁ Better fuel flexibility due to provision for adjusting heat

absorption

❁ Higher efficiency and reduced NOx emission even at part

load due to constant excess air

❁ Unique RH temperature control option

Bharat Heavy Electricals Limited TIRUCHIRAPALLI FBC & HRSG

 Presentation on CFBC Boilers

Comb. Temp.

With FBHE Without FBHE

FBHE

Combustor
Heat duty

Conv. Pass

Fuel Quality / Load

Bharat Heavy Electricals Limited TIRUCHIRAPALLI FBC & HRSG
 Presentation on CFBC Boilers

SINARMAS 175 t/h CFBC Boiler

• Fuel Coal (Imported+Indian)

• Commissioned March 1998

• Total hours logged 65,000

• Minimum load achieved

(without Oil support) 20 % MCR
• Controllability Range (achieved) 30 to 100%

• Generally in Continuous operation between planned annual

stoppages

Bharat Heavy Electricals Limited TIRUCHIRAPALLI FBC & HRSG

 Presentation on CFBC Boilers
Arrangement (Elevation) of Bilt Graphics CFBC Boiler

Bharat Heavy Electricals Limited TIRUCHIRAPALLI FBC & HRSG

 Presentation on CFBC Boilers

SLPP 2 x 125 MW CFBC BOILER

Location : Mangrol , Surat Dt , Gujarat

Fuel : Lignite ( 50 % M & 2.5 %S)

HHV - 2500 to 5500
Total hours logged : 65,000

Boiler Parameters
SH Steam : 390 T/H, 132 ATA, 540 0C
RH Steam : 350 T/H, 32.5 ATA, 540 0C

Bharat Heavy Electricals Limited TIRUCHIRAPALLI FBC & HRSG

 Presentation on CFBC Boilers
Arrangement (Plan) of SLPP CFBC Boiler

Bharat Heavy Electricals Limited TIRUCHIRAPALLI FBC & HRSG

 Presentation on CFBC Boilers
Arrangement (Elevation) of SLPP CFBC Boiler

Bharat Heavy Electricals Limited TIRUCHIRAPALLI FBC & HRSG

 Presentation on CFBC Boilers
View of 2 x 125 MWe SLPP

Bharat Heavy Electricals Limited TIRUCHIRAPALLI FBC & HRSG

 Presentation on CFBC Boilers

SLPP - Lignites Used

Fuel Design Actual

Fixed Carbon % 14 - 40 18 - 33
Volatile Matter % 25 - 44 21 - 26
Moisture % 10 - 50 41 - 48
Ash % 7 - 48 4-8
Sulphur* % 0.36 – 2.5 0.3 - 2

HHV kcal/kg 2500 -5500 2300 - 4775

Bharat Heavy Electricals Limited TIRUCHIRAPALLI FBC & HRSG

 Presentation on CFBC Boilers
SLPP Performance

Fuel Design Actual

Carbon % 43.30 30.75

Hydrogen % 3.14 3.48
Sulphur % 1.20 (2.5) 1.18
Nitrogen % 0.81 0.43
Oxygen (by diff.) % 8.53 7.61
Moisture % 24.00 42.44
Ash % 19.02 14.10

HHV kcal/kg 4250 3090

Chlorine content in Lignite Not identified 0.3-0.4%

Bharat Heavy Electricals Limited TIRUCHIRAPALLI FBC & HRSG

 Presentation on CFBC Boilers

RVUNL – Giral 125 MW

Bharat Heavy Electricals Limited TIRUCHIRAPALLI FBC & HRSG

 Presentation on CFBC Boilers
Comparison of SLPP – Giral
(Boiler parameters )

Parameter Unit SLPP Giral

Unit Rating MW 125 125

Type of Circulation Natural Natural

SH/RH Flow t/h 390 / 350 405 / 336

SH/RH Pres. kg/cm2 132 / 30.5 132 / 34
SH/RH Tem. Deg C 540 / 540 540 / 540
FW Tem. Deg C 235 237

Bharat Heavy Electricals Limited TIRUCHIRAPALLI FBC & HRSG

 Presentation on CFBC Boilers
Lignite Analysis - Comparison
SLPP Giral
Proximate Analysis (% by weight)
Moisture 24 10-50 40
Ash 19.02 7-48 15
Volatile Matter 32.52 25-44 20
Fixed Carbon (by diff.) 24.46 14-40 25
HHV, kcal/kg 4240 2500-5500 3000
Ultimate Analysis (% by weight)
Carbon 43.3 30.09
Hydrogen 3.14 2.24
Sulphur 1.2 (max 2.5) 6.00
Oxygen 8.55 6.27
Nitrogen 0.81 0.4
Moisture 24.0 40.0
Ash 19.02 15.0
Bharat Heavy Electricals Limited TIRUCHIRAPALLI FBC & HRSG
 Presentation on CFBC Boilers

Limestone Analysis - Comparison

SLPP Giral
Analysis (% by weight)
CaCO3 85.23 96.8
MgCO3 1.18 1.2
SiO2 8.65 1.15
Moisture 2.05 0.28
Others 2.89 0.57

Bharat Heavy Electricals Limited TIRUCHIRAPALLI FBC & HRSG

 Presentation on CFBC Boilers

Giral – Design Evolution

Bharat Heavy Electricals Limited TIRUCHIRAPALLI FBC & HRSG

 Presentation on CFBC Boilers

Giral CFBC Boiler Design - Evolution

• About 50 feedbacks from the operational

experience from SLPP and BILT
Graphics
• Learnings from 158 SARs from SLPP
and Bilt Graphics incorporated
• Discussions with Manufacturing and
OP&C groups
• Discussions with Erection Group -
PSWR

Bharat Heavy Electricals Limited TIRUCHIRAPALLI FBC & HRSG

 Presentation on CFBC Boilers
250 MW CFBC Flow Schematic

Bharat Heavy Electricals Limited TIRUCHIRAPALLI FBC & HRSG

 Presentation on CFBC Boilers
COAL
BUNKERS CONVECTIVE PASS

CYCLONES

SPECIAL
COMBUSTOR SEC. APH
( REGEN )
FBHE

250 MW CFBC Boiler

Bharat Heavy Electricals Limited TIRUCHIRAPALLI FBC & HRSG
 Presentation on CFBC Boilers
Gardanne 250 MW CFBC Plant

Bharat Heavy Electricals Limited TIRUCHIRAPALLI FBC & HRSG

 Presentation on CFBC Boilers

General Arrangement of 250 MW CFBC boiler

Bharat Heavy Electricals Limited TIRUCHIRAPALLI FBC & HRSG

 BHEL Presentation
- LEE on CFBC Boilers
Foster wheeler
PYROPOWER (IJT)
LLB (BHEL)
TO BACKPASS
TO BACKPASS
Fuel - Coal 800-1000C
870C 650-850C
850C CYCLONE
COMBUSTORWING WALL CYCLONE

CL- 2-3%
SH

CL- < 1.5% CFB COMBUSTOR

SOx - 150-250
SOx - 100
CFB COMBUSTOR

NOx - 50-200
NOx - 50
SEAL POT
SPIESS VALVE SECONDARY AIR
LOOP SEAL
SECONDARY AIR

700-900C
850C FUEL

FUEL FBHE
BHELAFBC PRIMARY AIR

PRIMARY AIR

CL < 3.5%
TBW
FBC

Krupp Industrie
DBW (KRUPP)

TO BACKPASS
FBC
SOx – 150-300
B&W (TBW )

IN FURNACE U-BEAMS SUPERHEATERS

U-BEAMSEP.

NOx – 200-300
300-400C CYCLONE
DIVISION WALL
TO BACKPASS

ECO 300-400C 650-790C

BED MATERIAL BIN

SH1
CFB COMBUSTOR FlyAsh reinjection
SH2
CL - 3-4% 150C
SOx - 150-300 SECONDARY AIR

SECONDARY AIR
CL - 3-4%
FUEL
NOx - 150-300 FUEL

SIPHON SEAL
700-870C SOx - 150-300
700-900C PRIMARY AIR

NOx - 150-300
PRIMARY AIR

SOx, Limited
Bharat Heavy Electricals NOx
FBC – in TIRUCHIRAPALLI
ppm FBC
FBC & HRSG
FBC
 Presentation on CFBC Boilers

Bharat Heavy Electricals Limited TIRUCHIRAPALLI FBC & HRSG