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CFBC
Circulating Fluidized Bed Combustion
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001 656p
Future utilization of oil and coal in utility and industrial powerstations depend on combustion systems which meet therequirement of an extensive reduction of emission
One solution with economical benefits is:
Circulating Fluidized BedCombustion
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History
141 267p
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 legislationTypically 200 mg/m NOX and 200 - 1,000 mg/m SO2 becamemandatory
later due to utilisation of opportunity fuels
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between Fixed Grate, Fluidized Bed,
and Pulverized Firing
Relationships
056 338p
Stoker Firing(Fixed Bed)
Fluidized Bed FiringBFB CFB
Gas
Fuel
Air Ash
Velocity 8 - 10 ft/ sec(2.3 - 3.0 m/ s)
4 - 10 ft/ sec(1.2 - 3.0 m/ s)
Average BedParticle Size
6,000 m
Pulverized Firing(Entrained Bed)
Gas
Fuel
Air
Ash
15 - 33 ft/ sec(4.6 - 10.0 m/ s)
50 m
Gas
Fuel &Sorbent
Air Ash
1,000 m 100 - 300 m
Gas
Fuel &Sorbent
Air Ash
15 - 23 ft/ sec(4.6 - 7.0 m/ s)
Air
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Environmentally friendly
CFB technology generates power :
High SO2 capture
Firing a wide variety of different fuels
Low NOx emissions
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SO2 Capture
CaCO3 --> CaO + CO2
CaO + SO2 + O2 --> Ca SO4
Furnace temperature control isvery critical
Limestone consumption variesenormously with furnace
temperature
Optimum temperature :850 C
850800 900
SO2Capture efficiency
T (C)
SO2 Captureachieved bylimestone injection
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NOx Emissions
- Combustion temperature
- N2 in fuel
- Excess air and staggering1 000800 1 200
NOx
T (C)
NOx Emissions influenced by3 main parameters :
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General Process
Bed temperature
AirAir
Air
Ash
Coal
Flue gas
Temperature maintained by heatpick up in exchange surfaces
Either in furnace
Or in FBHE
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CFB Boilers
1
32
7
4
5
6
8
9
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Main Design Criteria
High bed inventory of fine particles
High recirculation rate
Highly efficient cyclones
External and/or Internal heat exchangers for temperaturecontrol depending upon the application
Concept
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External Heat Exchangers
A very fine tuning of the bed temperature isnecessary
Fuel Analysis leads a small furnace
( Petroleum coke , Anthracites )
Very large electrical capacity CFB
Highly abrasive fuels
Concept
Advisable when :
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Furnace
F B H E
Cyclone
FBHE Design
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FBHE Design
Fluidisationair
Ashes fromcyclonesAshes to
furnace
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Wing Walls
Could be used as Evaporator HP superheater Final reheater
Furnace
Erosion protection
(refratory)
Tube-fin-tube
design
to cyclone
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Omega Panels
View from top
Double SuperOmega Design
Welded Design
Platen heaters within the furnace are a powerfulfeature:
To extract heat for superheating from the furnace
To have a self controlling system for furnace heatextraction (no mechanical control means needed)
To avoid erosion of heating surfaces by installationin the vertical flow area of the furnace and smoothsurface design
First unit has now gathered more than 100 000 hoperation with first platen heater equipment.
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CFD Analysisof Cyclone Performance
006 056px
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(Results from Simulation)
Fractional Collection Efficiency ofCollection Systems
056 287p
0%
20%
40%
60%
80%
100%
120%
0 50 100 150 200 250
d [m]
Collectionefficiency
Cyclone
alternative collection system
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Cyclone Improvement Measures
056 329p
DownwardInclinedInlet Duct
High PerformanceRefractory for Inlet Area
Eccentric VortexFinder Arrangement
Advanced VortexFinder Shape
Second Pass
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(Old and New Cyclone Design)
Particle Size Distributionof Solid Inventory
056 330p
10 m100 1000
Grain size d
0.1
1.0
(%)
10.0
20.030.040.050.0
60.0
70.0
80.0
90.0
99.0
99.9
ResidueR
old cyclone designnew cyclone design
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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
High Efficient Cyclone Benefits
056 343p
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Cyclone Arrangements
056 352p
< 100 MWel
200 - 300 MWel 300 MW - 400 MWel
100 - 200 MWel
600 MWel
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125 MWe, 250 MWe andBeyond
Class 150 MW
+ +
+ +
++
+ + +
+ + +
Class 350 MW Class 600 MW
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Performance of CFB boilers
EMILE
HUCHET
PROVENCE RED
HILLS
GOLDENBERG TAMUIN
OUTPUTMWe
FUEL
THERMALEFF.
DeSOx
NOxmg/Nm3
125 250 250 115 130
CoalCoal slurry Coal ( 4%S )Pitch Lignite Brown coal Petcoke
> 89 % > 94 % > 93 % > 89 % > 92 %
> 90 % > 97 % > 95 % > 95 % > 90 %
< 200 < 250 < 250 83 % (*)
> 95 % > 95 %
250 215
2002 2003
(*) HHV basis
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Emissions achieved CFBsin Relation to the Fuel Type
058 180p
Fuel Type NOX
mg/mstp, 6 % O2
SO2
mg/mstp, 6 % O2
DesulphurizationEfficiency
%
Anthracite & Anthracite tailings 70 220 80
Petcoke 100 200 97
Slurry 110 140 95
Bituminous Coal 80 200 95
Eastern US Bituminous Coal 60 100 97
High Moisture Lignite 140 200 90
High Sulphur Lignite 160 200 97
Biomass 100 - -
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Details
Ash Screw Cooler
056 341p
Holo-Flite Screw
Trough Jacket
Heat Exchanger
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Water Cooled Ash Cooler
056 323p
Return to furnace
Ash inlet duct fromfurnace bottom
Conveyor ash
to ash silo
Fluidizing air
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Split Loop Seal
056 232px
Coal
from Cyclone
to Furnace
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Major Recent References:
Utility Boiler
012 188p
Power Station Mlad Boleslav
2 x 50 MW
Energy Supply for VW-Skoda Factory
Technology - CFB
Fuel - BituminousCoal
Capacity t/h 2 x 140
Design Pressure bar 145
Temperature C 535
Commissioning - 1998
Country - Czech Republic
Customer - SKO Energo
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+ 53.0 m
0.0 m
Power Station Cao Ngan,2 x 50 MWLongitudinal Section
012 223p
Live Steam115 bar (design pressure)
538 C66 kg/s (237.6 t/h)
Feedwater223 C
Fuel
Vietnamese Lean CoalCustomer
VINACOAL, Vietnam
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Utility Boiler
012 183p
Major References:
Power Station Ledvice
110 MW
CFB Fired Boiler in Czech Republic
Technology - CFB
Fuel - Brown Coal
Capacity t/h 350
Design Pressure bar 135
Temperature C 545
Commissioning - 2001
Country - CzechRepublic
Customer - CEZ a.s.
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Major References:
Utility Boiler
012 185p
Power Station Emile Huchet
125 MW
CFB Fired Boiler in France
Technology - CFB
Fuel - BituminousCoal
Capacity t/h 367
Design Pressure bar 155
Temperature C 545/540
Commissioning - 1990
Country - France
Customer - SODELIF
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Major References:
Utility Boiler
012 187p
Power Station Goldenberg
125 MW
Extra large Furnace due to wet
(up to 60 % water) Brown Coal
Technology - CFB
Fuel - Lignite
Capacity t/h 400
Design Pressure bar 135
Temperature C 505
Commissioning - 1992
Country - Germany
Customer - RWE
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Akrimota, 2 x 125 MW
Boiler with CFB
012 217p
Live Steam138 bar538 C
405 t/hReheater Steam
36 bar537 C375 t/h
Feedwater247 C
FuelHigh SulphurLignite
0.0 m
+ 50.0 m
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Major References:
Utility Boiler
012 184p
Power Station Tamuin
2 x 130 MW
CFB Fired Boilers in Mexico
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
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Major References:
Utility Boiler
012 198p
RF#1
2 x 150 MW
CFB Fired Boilers in Taiwan
Technology - CFB
Fuel - Petroleum Coke
Capacity t/h 2 x 500
Design Pressure bar 149
Temperature C 541
Commissioning - 2002
Country - Taiwan
Customer - FHI
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Major Recent References:
Utility Boiler
012 154p
Power Station an
2 x 160 MW
First CFB Fired Boilers in Turkey
Technology - CFB
Fuel - Lignite
Capacity t/h 2 x 462
Design Pressure bar 199
Temperature C 543/542
Commissioning - 2002
Country - Turkey
Customer - TEAS
+ 56.7 m
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Major References:
Utility Boiler
011 422p
Tonghae Thermal Power Plant
2 x 220 MW
Reheat CFB Boilers in
Republic of Korea
Technology - CFB
Fuel - Anthracite
Capacity t/h 2 x 693
Design Pressure bar 172
Temperature C 541/541
Commissioning - 1998 and 1999
Country - Republic of Korea
Customer - Tonghae
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Major References:
Utility Boiler
011 424p
Power Station Provence
250 MW
First 250 MW CFB Boilers in the world
Technology - CFB
Fuel - Bituminous Coal
Capacity t/h 700
Design Pressure bar 193
Temperature C 565/565
Commissioning - 1995
Country - France
Customer - SOPROLIF
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Major References:
Utility Boiler
011 459p
Power Station Red Hills
2 x 250 MW
Technology - CFB
Fuel - Lignite
Capacity t/h 2 x 753
Design Pressurebar 203
Temperature C 540/568
Commissioning - 2001
Country - USA
Customer - Choctaw Generation
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Major References:
Utility Boiler
011 423p
Power Station Guayama
2 x 250 MW
Reheat CFB Boilers in Puerto Rico
Technology - CFB
Fuel - BituminousCoal
Capacity t/h 2 x 819
Design Pressure bar 207 Temperature C 540/540
Commissioning - 2003
Country - Puerto Rico
Customer - AES
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3 D Model
250 MW CFB for Indian Lignite
011 475p
Fuels for
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NCV
MJ/kg
Water content
Weight % a.r.
Ash content
Weight % a.r.
Sulphur
% maf
Anthracite 16 8 37
Bituminous coal 19 - 29 7 - 24 3 - 25
Lignite 12 - 18 12 - 42 12 - 26 5.5 - 12Brown coal 8 - 12 35 - 58 1 - 40 1 - 13
Special fuels:
Petcoke < 31.0 < 5 < 1 < 7
Wood chips 12 36 2
Coal slurry 10.5 33 30
Paper sludge 2.4 62 15
Sewage sludge 0.6 73 15
Bark 9 - 16 15 - 50 1 - 3 (20)
Fuels forCirculating Fluidized Beds
056 295p
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Reference Summary
141 269p
Fuels
Coal and ligniteWater content up to 60 %Ash content up to 40 %Sulphur content up to 13 % maf
various opportunity fuels
(coal, slurry, sewage sludge, petcoke, bark, ...)
Water/Steam side
Natural circulationAssisted circulation
Once-through (engineering study)With/without reheat up to 560 C
Capacity
From 70 MWth up to 250 MWel600 MWel under investigation
Advantages of CFB
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Advantages of CFBfor 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 temperatureand 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
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Lignite Fired CFB Plants
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 beensured 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
Conclusion
056 377p
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Summary
001 673p
CFB technology is well developed todayMore than 300 CFB plants are operating or are under constructionPlants with 250 MW capacity are running since 1995
CFB technology meets environmental requirementsNOX values less than 200 mg/m3 s.t.p. and desulphurizationefficiencies higher than 97 % could be achieved
CFB techhnology is able to burn a wide range of fuelsEspecially high sulphur and/or high ash or high water coals couldbe utilized
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