Internal Recirculation

Circulating Fluidised-Bed Boilers

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network spread over South East boiler for cement plants and internal-
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and the USA. boiler for power generation. The B&H Group
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The Technology of
Choice
Product Features
ƒƒ Compact, economical design and construction
ƒƒ Two stage separation for better bed inventory control
ƒƒ Impact separation with ‘U-beam’ particle separators
ƒƒ Best-in-class compliance with environmental norms
ƒƒ Low auxiliary consumption
ƒƒ Minimum refractory
ƒƒ Bottom-ash cooler (wet and dry)
ƒƒ No soot blowers
ƒƒ Multifuel firing capability

Operating Range
Capacity : Design pressure : Steam temperature :
Upto 1000 Tons/hr Upto 200 kg/cm2 (g) Upto 5600 C
i.e. 196 bar (g)

Fuels :
Coal, Lignite, Petroleum coke (petcoke), Sludge, Oil pitches, Biomass, Agro-wastes,
High–sulphur coal, Washery rejects, Mill rejects, Refused derived fuel, Char, Fly ash

Can be offered through following routes:

ƒƒ Boiler island
ƒƒ Boiler-Turbine-Generator (BTG) package
ƒƒ Turnkey power plant (EPC)

Thermax IR-CFBC test facility (2 MWth) at Pune, India

IR-CFBC design offered to power / process plants
seeking economy, reliability & flexibility
Internal Recirculation – Circulating Fluidised Bed
Boiler (IR-CFBC) – The Latest Design

Steam Drum

Division Wall
Secondary Superheater (Near Side)
In-furnace-U-Beams Primary Superheater (Far Side)

Wing Wall Particle Transfer Hopper

Economiser
Refractory Line
Dust Collector
Fuel Silo

Ash Recycle System

Tubular Air Heater

Fuel Feeder Secondary Air Duct

Fuel Chute
Air
Gas
Water Flue Gas
Steam
Overbed Burners
Primary Air Duct
Ash Cooler
Improves Performance,
Reduces Costs,
Minimises Maintenance
Two-Stage Particle Separation for Superior Combustion
Efficiency
The unique IR-CFBC boiler design employs a patented two-stage particle separation
system to provide high-solids loading and a uniform furnace temperature profile.
The benefits of this technology include superior combustion efficiency, high
operational thermal efficiency, low emissions, low maintenance, low pressure drop,
and high turndown, resulting in improved overall plant performance. Our two-stage
system includes a primary U-beam impact separator and a secondary multi-cyclone
dust collector (MDC) which work together to provide a combined particle collection
efficiency in excess of 99.8%. The U-beams, a staggered array of stainless steel
channels at the furnace exit plane, capture nearly all of the solids suspended in
the flue gas leaving the furnace and internally recirculate these solids to the lower
furnace. The ceramic MDC, with small diameter 250 mm cyclones, captures the
solids in second pass and returns this material to the lower furnace in a controlled
manner. The ability to regulate the secondary recycle system provides the operator
with unprecedented furnace temperature control, resulting in improved boiler
performance and relatively faster load response.

U-Beams
(Primary Particle Collector)

Primary All-internal
Recirculation Loop

Bed
Solids

To ESP or
Baghouse
Multi-Cyclone
Dust Collector
(Secondary
Fuel and Particle
Sorbent Collector)

Secondary
Recirculation Loop

The two-stage particle

Bed Drain
collection system provides
improved performance, as well
as a simplified, cost-effective
boiler design.
Compact, Economical Design Sidewall Membrane Panel

The two-stage particle separation

system results in a compact, simplified Thin Refractory
boiler arrangement. The entire
U-beam particle separator is located Seal
Baffle
at the furnace exit. Compared with
Gas Flow
hot cyclone-type CFBC designs,
the IR-CFBC has significantly lower
furnace exit gas velocity and requires Gas
significantly less building volume. By Plus
Solids
relying on internal recirculation, the Flow
IR-CFBC design eliminates J-valves, loop
seals, high-pressure blowers, and soot
blowers, which are required with other U-Beam
CFBC designs.
Water-Cooled
Support Tube
Higher Availability, Lower
Maintenance
One goal of CFBC boiler manufacturers
has been to eliminate thick, uncooled Gas
Flow
refractory and hot expansion joints
from their designs to reduce the
expense and lost time associated with
refractory maintenance. This goal
was achieved with the development
of the IR-CFBC boiler. The furnace,
U-beam separator, and superheater
enclosures are constructed entirely of
top-supported, gas-tight, all-welded
membraned tube walls which do not
require hot expansion joints. The small
amount of refractory that is used in the U-Beams
IR-CFBC is applied to selected areas of
the water-cooled enclosure surface in In-Furnace
U-Beams
a thin layer which is only 16 mm thick
in the lower furnace slightly thicker
over the tube face elsewhere in the
furnace. As a result, IR-CFBC requires
only 10 to 25% of the total refractory Furnace
found in a hot cyclone CFBC design
Gas and
and less than 50% of the refractory Solids Flow
used in a water-cooled or steamcooled
cyclone CFBC unit. This construction The U-beam primary particle collection
has significantly reduced the need for system recirculates more than 97% of the
refractory maintenance in operating solids suspended in the flue gas back to
CFBC units.
the lower furnace.
No Interface Erosion
The patented reduced diameter zone (RDZ) tube section is another feature
designed to reduce maintenance. The RDZ consists of a reduced diameter
tube section mating to a specially-shaped ceramic tile. The reduced diameter
tube section on each tube slopes away from the solids falling down the wall.
This eliminates the solids material from building up and eroding the furnace
tubes where the lower furnace refractory ends.

Wall
Tubes
Ceramic
The reduced diameter zone tube
Tile section has proven to reduce
maintenance by eliminating
localised erosion at the refractory
interface in the lower furnace.

Pin Studs Thin

(To Anchor Refractory
and Cool
Refractory)

Low Flue Gas Velocities to Reduce Erosion

Erosion is a major cause of maintenance problems in CFBC boilers due to the
high solids loading in the flue gas. The severity of this erosion is exponentially
related to the velocity of the flue gas through the system. On hot cyclone
CFBCs the particle separator depends upon an extremely high flue gas
velocity to provide the energy needed to efficiently disengage the particles
from the flue gas. By comparison, the U-beam particle separator is designed
to operate efficiently with much lower flue gas velocity at full-load operating
conditions. The particle capture efficiency actually increases as the flue gas
velocity through the U-beam separator decreases. By operating at such a low
gas velocity, the potential for erosion in the IR-CFBC is significantly reduced.
To date, because of proper material selection and low flue gas velocities,
the U-beam separators have not required any maintenance due to erosion
throughout years of operation at design load conditions.

The secondary multi-cyclone

dust collector in the two-stage
particle separation system provides
Individual Gas
Outlet Hoods increased collection efficiency of
fine particles. By locating the dust
collector immediately upstream of
the economiser in a region of cooler
flue gas, and by using high hardness
High Hardness wear resistant material, maintenance
Collection Components is minimal. The design also
permits easy access to all internal
components.
Fluidised-Bed
Technologies
to Meet Every
Need
There is no substitute for actual operating
experience. Thermax has that experience and
a proven track record of high availability for
all types of boiler technologies – including
fluidised–bed combustion technologies such as –
circulating (IR–CFBC) and bubbling (BFBC).

Bubbling Fluidised-Bed Combustion

Technology
For fuels with high moisture contents and
low heating values such as sludges and high
moisture biomass, Thermax recommends the
use of bubbling fluidised-bed combustion (BFBC)
technology. Thermax offers an open hopper
bottom BFBC design which is ideal for burning
fuels containing large pieces of noncombustible
material, such as rocks and metal pieces.
BFBC technology also is well-suited for retrofit
applications on stoker-fired or chemical recovery
boilers.

Innovative Energy Solutions

Thermax is committed to the continuing
advancement of its fluidised bed technologies.
This commitment is demonstrated through
continued research and development. In
addition, field demonstrations and testing
have led to many improvements that are now
implemented into our design standards as well as
our operating CFBC and BFBC boilers.
Features and Benefits
IR-CFBC Design Features
Two-stage particle separation system
All-internal primary solids recirculation
(U-beams)
Low, uniform velocities at the furnace exit
U-beam separators, and the superheater
No thick refractory due to elimination of hot
cyclones and hot return legs
In-furnace heat transfer surface
Unique primary air nozzles (bubble caps)
Sootblowers not required upstream of MDC
Gravity fuel feed and fly ash recycle system
High turndown (up to 5:1) without auxiliary fuel
support
IR-CFBC Design Benefits and Operating Results
ƒ Greater than 99.8% particle collection efficiency
ƒ Provides a means to control particle size distribution in
furnace, which results in improved carbon burnout, limestone
utilisation, emissions and heat transfer
ƒ Reduces operating costs
ƒ Compact design requires 20-30% less building volume than
cyclone-based CFBC boilers — critical for repowering projects
ƒ Lowers auxiliary power consumption compared with cyclone-
based CFBC boilers
ƒ Significantly reduces erosion in upper furnace and
superheater compared with cyclone designs
ƒ To date, no U-beam erosion maintenance required in any
IR-CFBC unit
ƒ No high-maintenance vortex finders or hot expansion joints;
therefore, no maintenance expenses for these items
ƒ Thin, cooled refractory places no restriction on boiler start-up
or shut–down rate
ƒ Significantly reduces need for refractory maintenance
ƒ Virtually eliminates forced outages due to refractory failures
ƒ Requires only 10 to 25% of the total refractory compared
with hot cyclone CFBC designs
ƒ Vertical, flat membraned tube panels within furnace perform
evaporative or superheat duty
ƒ Proven reliability and low maintenance
ƒ Reduces back sifting of solids during low-load operation
ƒ Reduces need for periodic cleaning of nozzles and primary air
windbox
ƒ Minimises erosion inside nozzle caused by the re-entrainment
of back-sifted solids
ƒ Eliminates steam consumption, maintenance costs and forced
outages typically associated with sootblowers
ƒ Reduces maintenance, forced outages and auxiliary power
requirements by eliminating the mechanical fuel injection and
pneumatic fly ash recycle systems
ƒ Allows wider load swings
ƒ Reduces operating costs (no auxiliary fuel) during low–load
operation
Fuel Flexibility,
Lower Emissions
Fuel Flexibility
One of the main advantages of CFBC technology
is that it allows the owner to specify a wide variety
of fuels to optimise the profitability of the facility.
Thermax has the engineering expertise and operating
experience needed to supply an IR-CFBC boiler that is
capable of burning specified fuels, such as:

ƒƒ Coal
ƒƒ Lignite
ƒƒ Petroleum Coke (petcoke)
ƒƒ Washery Rejects
ƒƒ Mill Rejects
ƒƒ Agro-Waste
ƒƒ Biomass
ƒƒ Refuse Derived Fuel
ƒƒ Char

Other fuels such as fly ash and sludge are also

candidates, depending on their percentage of heat
input, moisture content and emission requirements.
The IR-CFBC boiler also can be designed to burn
several specified fuels in the same unit. This provides
the additional flexibility needed to respond to changes
in the fuel markets.

Emissions Control
The IR-CFBC boiler can control SO2 emissions by
injecting limestone into the lower furnace. Relatively
low NOx emissions are inherent in the IR-CFBC due
to low and uniform furnace temperatures and staged
combustion. NOx emissions can be further reduced
by using a selective non-catalytic reduction (SNCR)
system. In addition, the IR-CFBC’s patented secondary
particle recycle system provides increased control,
not found in other CFBC technologies, to maintain
an optimum uniform furnace temperature which is
essential for low SO2 and NOx emissions and for better
limestone utilisation.
 North America South America Europe Africa
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Mexico Colombia Germany Egypt
U.S.A Ireland Kenya
Netherlands Nigeria
Turkey South Africa
Tanzania
Zambia

Installations in 75 countries
Global Footprint of Boiler & Heater Group
For more details visit www.thermaxglobal.com
or Write to bnhenquiry@thermaxglobal.com or
enquiry@thermaxglobal.com
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www.thermaxglobal.com

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