IR-CFBC Boiler Design &

Concept

Jayaraman Rajavel
Thermax Ltd., Pune

25th June 2010

IR-CFBC Boiler Conference
 Outline

Concept of IR-CFBC boiler

Comparison between CFBC and AFBC boiler
technologies

Features of IR-CFBC design

Comparison of various CFBC technologies
Fluidization concept
Fluidization concept
 WHY CFBC BOILER ?

 HIGH THERMAL EFFICIENCY

 EFFECTIVE REDUCTION OF Sox EMISSIONS

THROUGH LIME INJECTION

 REDUCTION OF NOX FORMATION BY

REDUCED THERMAL NOX GENERATION

 REDUCED CO EMISSION LEVELS

 FUEL FLEXIBILITY

CFBC.PPT-8
 Better combustion- Why?

Uniform combustion temperature

High Turbulence in bubbling bed zone

Higher Residence time

Smaller fuel particles.
 Emission..

Controlled combustion temperature

Sox control through Lime addition

Nox control through lower operating
temperature

Staging of combustion

Lower excess air utilization
 Fuel Flexibility.

COAL

LIGNITE

WASHERY REJECTS

CHAR

PETCOKE

BIOMASS

INDUSTRIAL REJECTS (CHAR ,ETP SLUDGE
ETC).

OIL

GAS
 B&W IR-CFBC Boiler
Fuel Flexible Technology

Accepts wide range of fuels

Volatile matter, % 4 40
Ash, % 0 70
Heating value, Kcal/kg > 1500
Moisture, % < 55

Use of lower rank fuels reduces fuel costs

Fuel flexibility - minimizes fuel supply uncertainties
Ability to burn low cost and waste fuels
 Difference between
AFBC and CFBC

Circulating bed, burning particles travel entire
furnace

Particle separation device ( U-beam ,
cyclone) is used, solids are recycled.

No heating surfaces are provided in the bed (
which are prone for erosion)
 Difference between AFBC and
CFBC Design parameters

Low temperature

High residence time

Air split

High heat transfer rate

Uniform furnace temperature

Low un-burnt carbon in ash

Bed material size

Lime stone size

Bed velocity
 Internal Recirculation Circulating Fluidized Bed
Combustion Boiler

Boiler
System
Overview
 B&W Internal Recirculation - Circulating
Fluidized Bed Combustion Boilers

A simplified approach to
improved flexibility and
reliability

Design Features
High combustion
efficiency
Compact, economical
design
Higher reliability and
availability
Lower maintenance
costs
Reduced erosion
Fuel flexibility
Low emissions
U-Beam Separators
1 4

1. Sidewall

membrane panel

2. U-beam - SS309H/ Flue 3
Flue

SS310H/RA253MA Gas Gas
&

3. Seal baffle Solid
Flow
2

4. Refractory
U-BEAMS IN IR-CFBC BOILER
 U-Beam Separators

SEGMENTAL U BEAMS
 IR-CFBC U-Beam Segments

U-Beams

Water-cooled
Support
Tubes
Multicyclone Secondary Collector
(Mechanical Dust Collector or MDC)

Proven modular design

Predictable high
performance
Low maintenance

Easy access

High hardness cyclone
tubes

No refractory
 Multicyclone Secondary Collector
(Mechanical Dust Collector or MDC)

High-hardness alloy casting

Ceramic shape
Overall Grade Separation
Efficiency Comparison

B&W IR-CFBC Two Stage Solids
Collection vs Hot Cyclone CFBC Collection
100

90
B&W
IR-
Efficiency, %

80 CFBC

Cyclone
70
-Based
CFBC
60

50

40
0 20 40 60 80 100 120
Particle Size, Micron
B&W IR-CFBC Two-Staged Solids
Separation System

Benefits
High overall solid collection efficiency ~ More
than 99.7%
Precise furnace temperature control ~ By
controlling solid recycle rate from the
secondary collector
Extended turndown ratio without use of
auxiliary fuel (oil/gas) ~ 100% to 20% MCR
Low auxiliary power requirements compared
to cyclone-based CFBC technologies ~ 2-4
w.c. (50-100 mm w.c.)
 Thin Cooled
Refractory

Low gas velocity through

U-beam collector significantly
reduces need for refractory

(Refractory highlighted in yellow)

 Lower Furnace Refractory
Construction
Studs anchor and
cool the thin layer
of refractory
Minimal refractory
maintenance
 Refractory Reduced Diameter Zone

Significant reduction in tube

and refractory erosion at
refractory interface

Pin studs & refractory highlighted in yellow

Typical
Bubble
Cap
Fluidizing
air jets

Bubble
Cap Bed
 CFBC Boiler Design Comparison
B&W IR-CFB
Solids Separation System Two-stage (100%
efficiency for particles of
d>80 micron*)
Hot-Cyclone Integral Cyclone Cold-Cyclone
Single-stage (100% Single-stage (100% Single-stage (100%
efficiency for particles of efficiency for particles efficiency for particles of
d>100 micron) d>100 micron) d>100 micron)

* Recycling finer particles increases furnace heat transfer rate, improves combustion efficiency and limestone utilization.

Upper Furnace Density lb/ft3 (kg/m3) 0.7 1.0 0.5 0.7 0.5 0.7 0.3 0.5
(11 16) (8 11) (8 11) (5 8)

Furnace Temperature Control
Desired temperature can
be maintained within +/-
10 F interval for wide range
of fuels and operating
conditions by adjusting
secondary recycle rate.
Temperature is pre-
determined by furnace
and heat exchanger
design along with fuel
and limestone properties
and sizing.
Temperature is pre-
determined by furnace
and heat exchanger
design along with fuel
and limestone properties
and sizing.
Lower bed temperature
is controlled by adjusting
cold cyclone ash recycle
rate. Temperature span
across furnace height is
up to 200 F.

Boiler Turndown Without 5:1 3.5 : 1 3.5 : 1 3.5 : 1

Auxiliary Fuel

Refractory:
Thickness, in. (mm) 0.6 2.0 (15 50) ~3 (~75) on studded tubes ~3 (~75) ~2 (~50)
8-12 (200-300) on casing

Covered Areas Lower furnace, U-beam Lower furnace, cyclone Lower furnace, cyclone Entire furnace, cyclone
zone enclosure walls recycle loop (5 10 times recycle loop (3 5 times (3 4 times more than @
more than @ B&W CFB) more than @ B&W CFB) B&W CFB)

Hot-Temperature Expansion Joints None 3 5 per cyclone Number varies with arrangement None

Furnace Shaft Velocity 15 18 16 18 16 18 13 15

[Design Range] , ft/s (m/s) (4.9 5.5) (4.9 5.5) (4.9 5.5) (4.0 4.5)

Furnace Exit Velocity, ft/s (m/s) 21 23 75 85 75 85 N/A

(6.4 9.8) (22 26) (22 26) N/A

High-Pressure Air Not required Required for J-valves Required for J-valves Required for siphons

Total Pressure Drop Across Solids 4 (1.0) 6 8 (1.5 2.0) ~6 (~1.5) 4 6 (1.0 1.5)
Separator(s), in. wc (kPa) (U-beams + MDC)

Auxiliary Power Consumption Lower Higher Higher Moderate

IR-CFBC Features / Benefits
Highupper furnace heat transfer rate and precise
furnace temperature control

AND

Extended turndown ratio (no oil/gas) 100% to 20%

MCR

Are both the result of the B&W IR-CFB two stage solids collection /
recycle system characteristics

Low auxiliary power requirements

Due to low flue gas P and no fluidizing blower
IR-CFB Features / Benefits

Fast shut down / cool down

80%+ of bed material is drained during cooldown. Can shutdown / cool /
enter / re-start within a 24 hour period compared to 2 to 3 times longer for
other CFB design types

Low Maintenance Costs

No refractory maintenance, no hot expansion joints, no fluidized sealing
system, low furnace exit velocity, low gas velocity in convective heating
surfaces
 FEATURES OF INTERNAL RECIRCULATION CFB

INTERNAL RECIRCULATION - MORE THAN 95 % BY U - BEAMS

U-BEAMS OF SS 309H / SS253 MA MATERIAL - NO MAINTENANCE
HIGH TEMP WITHSTAND CAPACITY ( 940deg.C)

LESS REFRACTORY WORK (Only 15% as - ALLOWS QUICK START UP

compared to cyclone design CFB) - LESS OIL CONSUMPTION
WITH CYCLONE DESIGN CFBs

LOWER POWER CONSUMPTION - Draft loss across U-BEAMS - 1 INCH

- Draft loss across CYCLONE - >5 INCH
LOW GAS VELOCITY - IN U-BEAM AREA 5 TO 6 m /s
- CYCLONE INLET 20 TO 25 m / s

CONTROLLED EXTERNAL FLY ASH RECYCLE - FASTER LOAD RESPONSE

WITHIN +/- 15 DEG.C FROM TOP - FURNACE TEMP. IS MAINTAINED TO BOTTOM OF
FURNACE

WATER NOT REQUIRED FOR - FD AIR COOLES BED ASH IN FLUID BED BED ASH
COOLING COOLER

GAS RECIRCUL. NOT REQUIRED - PARTICULATE COLLECTION EFF. OF U-BEAMS

IMPROVES AT PART LOADS

ROOTS BLOWER NOT REQUIRED - FUEL IS INJECTED TO FURNACE WITH FD AIR

PRESSURE
 ADVANTAGE OF CFBC BOILER FROM TBW

 HIGH INTERNAL CIRCULATION

Improved furnace performance
High operating efficiency
 LOW EXTERNAL CIRCULATION
No J valve / L valve
Finer control on performance
 COMPACT PRIMARY COLLECTOR
Small footprint area
Boiler plant size reduced
 NO THICK REFRACTORY
Quick start up
 TOP SUPPORTED INTEGRATED UNIT
No hot expansion joints
Reduced maintenance
 UNIFORM LOW VELOCITY IN FURNACE & SUPERHEATER
CFBC.PPT-7 Reduces potential for erosion
Reduced maintenance
 LOWER MAINTENANCE - HIGH AVAILABILITY - BETTER
RELIABILITY

LESS USE OF REFRACTORY (TYPICALLY 75 TONS VS 450) (NO THICK REFRACTORY)

FLUID BED ASH COOLER - NO MOVING PARTS
AIR -SWEPT COAL FEEDER- NO MOVING PARTS
METAL COATING / RDZ FOR REFRACTORY INTERFACE- COUNTERS EROSION
BETTER S/H SUPPORT SYSTEM USED FOR ENHANCED RELIABILITY - NO SLINGER TUBES PRONE TO
EROSION
DENSE STUDS PATTERN (96 per Ft2)- BETTER HEAT TRANSFER - BETTER REFRACTORY ADHERENCE
NO REFRACTORY LINED DIP - LEG, J, L VALVE HIGH MAINTENANCE ITEM ELIMINATED
TRADITIONAL PENDANT VERTICAL LEG SUPERHEATER - NO FOULING
NO SOOT BLOWERS REQUIRED - LESS MAINTENANCE -SAVING IN BLOW STEAM
LOW GAS VELOCITY IN CONVECTION PASS. NO EROSION OF PRESSURE PARTS
LOW GAS VELOCITY AND IN-LINE ARRANGEMENT OF ECONOMISER AND AIR HEATER TUBES REDUCED
EROSION POTENTIAL
ASH RECYCLE SYSTEM (MDC) GIVES FASTER LOAD CHANGE RESPONSE.
LOWEST NOX EMISSION LEVEL IN THE INDUSTRY -<100 PPM
THANKS