CFBC

Circulating Fluidized Bed Combustion

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

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/m NOX and 200 - 1,000 mg/m SO2 became mandatory later due to utilisation of opportunity fuels

141 267p

Relationships
between Fixed Grate, Fluidized Bed, and Pulverized Firing
Stoker Firing (Fixed Bed) Fluidized Bed Firing BFB CFB
Gas Gas Gas

Pulverized Firing (Entrained Bed)

Gas

Fuel

Fuel & Sorbent

Air Fuel & Sorbent Air Ash 4 - 10 ft/ sec (1.2 - 3.0 m/ s) 1,000 m Air Ash 15 - 23 ft/ sec (4.6 - 7.0 m/ s) 100 - 300 m

Air Fuel

Air Ash Velocity 8 - 10 ft/ sec (2.3 - 3.0 m/ s)

Ash 15 - 33 ft/ sec (4.6 - 10.0 m/ s) 50 m

Average Bed Particle Size

056 338p

6,000 m

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 limestone injection
CaCO3
CaO + SO2 + O2
Optimum temperature : 850 C

--> CaO + CO2

--> Ca SO4

SO2Capture efficiency

Furnace temperature control is very critical

Limestone consumption varies enormously with furnace temperature

800

850

900

T (C)

NOx Emissions

NOx Emissions influenced by 3 main parameters : NOx

- Combustion temperature

- N2 in fuel
- Excess air and staggering 800 1 000

T (C)
1 200

General Process
Flue gas

Bed temperature

Coal Temperature maintained by heat pick up in exchange surfaces Either in furnace Or in FBHE Air As h

Air

Air

CFB Boilers

8 4

7 2 3 5

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 to furnace

Ashes from cyclones

Fluidisation air

Wing Walls

to cyclone

Could be used as Evaporator HP superheater Final reheater

Tube-fin-tube design Erosion protection (refratory) Furnace

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 Omega Design Welded Design

CFD Analysis of Cyclone Performance

006 056px

Fractional Collection Efficiency of Collection Systems

(Results from Simulation)
120%

100%

Collection efficiency

80% Cyclone 60%

40% alternative collection system 20%

0% 0 50 100 d [m]
056 287p

150

200

250

Cyclone Improvement Measures

Second Pass Eccentric Vortex Finder Arrangement Downward Inclined Inlet Duct Advanced Vortex Finder Shape

High Performance Refractory for Inlet Area

056 329p

Particle Size Distribution of Solid Inventory

(Old and New Cyclone Design)
0.1 1.0 (%) 10.0 20.0 30.0 40.0 50.0 60.0 70.0 80.0 new cyclone design old cyclone design

Residue R

90.0

99.0

99.9 10 100 Grain size d

056 330p

1000

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
< 100 MWel 100 - 200 MWel

200 - 300 MWel

300 MW - 400 MWel

600 MWel

056 352p

125 MWe, 250 MWe and Beyond

+ + + + + + +

+
Class 150 MW Class 350 MW

+
Class 600 MW

Performance of CFB boilers

EMILE HUCHET PROVENCE RED HILLS CAN GOLDENBERG AKRIMOTA TAMUIN

1991

1996
250

2001
250

2002
160

1992
115

2003
125

2002
130

OUTPUT MWe FUEL THERMAL EFF. DeSOx NOx mg/Nm3

(*) HHV basis

125

Coal Coal slurry

Coal ( 4%S ) Pitch

Lignite

Lignite

Brown coal

Lignite

Petcoke

> 89 %

> 94 %

> 93 %

> 92 %

> 89 %

> 83 % (*)

> 92 %

> 90 %

> 97 %

> 95 %

> 95 %

> 95 %

> 95 %

> 90 %

< 200

< 250

< 250

250

<200

215

<200

Emissions achieved CFBs in Relation to the Fuel Type

Fuel Type

NOX mg/mstp, 6 % O2

SO2 mg/mstp, 6 % O2 220 200 140 200 100 200 200 -

Desulphurization Efficiency % 80 97 95 95 97 90 97 -

Anthracite & Anthracite tailings Petcoke Slurry Bituminous Coal Eastern US Bituminous Coal High Moisture Lignite High Sulphur Lignite Biomass

70 100 110 80 60 140 160 100

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 furnace Ash inlet duct from furnace bottom

Conveyor ash to ash silo

056 323p

Fluidizing air

Split Loop Seal

from Cyclone Coal

to Furnace

056 232px

Utility Boiler
Major Recent References: Power Station Mlad Boleslav 2 x 50 MW Energy Supply for VW-Skoda Factory
Technology Fuel Coal Capacity Design Pressure Temperature Commissioning Country Customer
012 188p

t/h bar C -

CFB Bituminous 2 x 140 145 535 1998 Czech Republic SKO Energo

Power Station Cao Ngan, 2 x 50 MW

Longitudinal Section
+ 53.0 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

012 223p

0.0 m

Utility Boiler
Major References: Power Station Ledvice 110 MW CFB Fired Boiler in Czech Republic
Technology Fuel Capacity Design Pressure Temperature Commissioning Country Republic Customer
012 183p

t/h bar C -

CFB Brown Coal 350 135 545 2001 Czech CEZ a.s.

Utility Boiler
Major References: Power Station Emile Huchet 125 MW CFB Fired Boiler in France
Technology Fuel Coal Capacity Design Pressure Temperature Commissioning Country Customer
012 185p

t/h bar C -

CFB Bituminous 367 155 545/540 1990 France SODELIF

Utility Boiler
Major References: Power Station Goldenberg 125 MW Extra large Furnace due to wet (up to 60 % water) Brown Coal

012 187p

Technology Fuel Capacity Design Pressure Temperature Commissioning Country Customer

t/h bar C -

CFB Lignite 400 135 505 1992 Germany RWE

Akrimota, 2 x 125 MW
Boiler with CFB
+ 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
0.0 m
012 217p

Utility Boiler
Major References: Power Station Tamuin 2 x 130 MW CFB Fired Boilers in Mexico

012 184p

Technology - CFB Fuel - Petroleum Coke Capacity t/h 2 x 395 Design Pressure bar 154 Temperature C 540/540 Commissioning - 2002 Country - Mexico Customer - SITHE-IPG

Utility Boiler
Major References:
RF#1&#2 2 x 150 MW CFB Fired Boilers in Taiwan

012 198p

Technology - CFB Fuel - Petroleum Coke Capacity t/h 2 x 500 Design Pressure bar 149 Temperature C 541 Commissioning - 2002 Country - Taiwan Customer - FHI

Utility Boiler
Major Recent References:
+ 56.7 m

Power Station an 2 x 160 MW First CFB Fired Boilers in Turkey

Technology Fuel Capacity Design Pressure Temperature Commissioning Country Customer t/h bar C CFB Lignite 2 x 462 199 543/542 2002 Turkey TEAS

012 154p

Utility Boiler
Major References: Tonghae Thermal Power Plant 2 x 220 MW Reheat CFB Boilers in Republic of Korea

011 422p

Technology Fuel Capacity Design Pressure Temperature Commissioning Country Customer

t/h bar C -

CFB Anthracite 2 x 693 172 541/541 1998 and 1999 Republic of Korea Tonghae

Utility Boiler
Major References: Power Station Provence 250 MW First 250 MW CFB Boilers in the world

011 424p

Technology Fuel Capacity Design Pressure Temperature Commissioning Country Customer

t/h bar C -

CFB Bituminous Coal 700 193 565/565 1995 France SOPROLIF

Utility Boiler
Major References:
Power Station Red Hills 2 x 250 MW

011 459p

Technology Fuel Capacity t/h Design Pressurebar Temperature C Commissioning Country Customer -

CFB Lignite 2 x 753 203 540/568 2001 USA Choctaw Generation

Utility Boiler
Major References: Power Station Guayama 2 x 250 MW Reheat CFB Boilers in Puerto Rico
Technology Fuel Coal Capacity Design Pressure Temperature Commissioning Country Customer
011 423p

t/h bar C -

CFB Bituminous 2 x 819 207 540/540 2003 Puerto Rico AES

250 MW CFB for Indian Lignite

3 D Model

011 475p

Fuels for Circulating Fluidized Beds

N CV MJ/ kg Anthracite Bituminous coal Lignite Brown coal Special fuels: Petcoke Wood chips Coal slurry Paper sludge Sewage sludge Bark < 31.0 12 10.5 2.4 0.6 9 - 16 16 19 - 29 12 - 18 8 - 12

Wa ter content Weight % a .r. 8 7 - 24 12 - 42 35 - 58

Ash content Weight % a .r. 37 3 - 25 12 - 26 1 - 40

Sulphur % ma f

5.5 - 12 1 - 13

< 5 36 33 62 73 15 - 50

< 1 2 30 15 15 1 - 3 (20)

< 7

056 295p

Reference Summary
Fuels Coal and lignite Water content up to Ash content up to Sulphur content up to 60 % 40 % 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

Therefore, flue gas exit temperature of 140 C or less

056 374p

Lignite Fired CFB Plants

Conclusion

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