2.8 Combustion Air System

Asiakirjan nimi - Name of Document Tunniste - Identification Rev.
PROCESS DESCRIPTION CFBT-582-1 1

2.8 COMBUSTION AIR
Osasto - Department Kohde - Subject Sivu - Page
Power Generation RAPP PB3 PROJECT 1 (26)

Systems CFB MULTIFUEL BOILER
TABLE OF CONTENTS
2.8 COMBUSTION AIR SYSTEM ....................................................................... 2
2.8.1 Purpose of the system ................................................................................ 2
2.8.2 General description of the system............................................................. 2
2.8.3 Design criteria............................................................................................ 12
2.8.4 Equipment specification ........................................................................... 13
2.8.4.1 Air fans ........................................................................................................ 13

2.8.4.2 Steam coil air preheater .............................................................................. 21
2.8.4.3 Flue gas air preheaters................................................................................ 22
2.8.4.4 Air nozzles ................................................................................................... 24
1 2005 - 08 - 30 T. Anttonen
0 2005 - 03 - 09 T. Anttonen
Muut. Pvm Laatinut Pvm Tarkastanut Pvm Hyväksynyt
Rev. Date Prepared by Date Reviewed by Date Approved by
KLY-1 1997-05 P:\582-RAPP-PB3\int\Kayttoonotto\koulutus\Training Manuals\Folder 1\2.8 Combustion air system(1).doc

This document is the exclusive intellectual property of Kvaerner Power Oy and is furnished for the sole purpose of operating and maintaining of the specific project, and re-use of the document for any other project
or purpose is prohibited. The document or the information shall not be reproduced or copied, or disclosed to a third party without prior written consent of Kvaerner Power Oy.
© Kvaerner Power Oy, Tampere, Finland 2005

2.8 COMBUSTION AIR

2.8 COMBUSTION AIR SYSTEM
Flowsheets: T582-00017 Combustion air

T582-00018 Cyclones
T582-00020 Steam coil air preheater
T582-00021 Fluo seals
T582-00041 Oil lubrication units of the
primary air fans
2.8.1 Purpose of the system
The purpose of the combustion air system is

− to supply the right amount of air needed for combustion into
the boiler furnace at all specified boiler loads and with all
design fuels
− to distribute combustion air according to process requirements
− to fluidize the bed material in the furnace and in the fluo seals
2.8.2 General description of the system
The air system of the boiler consists of:

− air ducts with accessories
− primary air (fluidizing air) fans, 2 pcs (283K005, 283K006)
− secondary / burner air fans, 2 pcs (283K007, 283K008)
− steam air preheater for primary air (283E078)
− flue gas air preheaters for primary air (283E069, 283E070)
− primary air nozzles
− secondary air openings
− fluo seal (loop seal) fluidizing air blowers, 2 pcs (283K009,
283K010)
− fluo seal air nozzles

2.8 COMBUSTION AIR

Air distribution
The combustion air is divided into primary (fluidizing) air, over fire
(secondary) air and fluo seal fluidizing air. The combustion air for
the start-up burners (from 283E059 to 283E064) is supplied from
the secondary air system.
Combustion air distribution to different locations depends mainly

on fuel (coal / biofuel) and boiler load. Boiler control system
takes care of air distribution according to preset values but in
some operation situations fine tuning may be required by the
operators.
The staging air, which completes the combustion, is introduced

through secondary air ports located at two levels on front and
rear walls of the furnace (283E065). The first level is located
directly above the bed and the second is above the fuel feeding
openings few meters above the bottom. Lower level is mainly
used during coal firing since air injected through lower level
penetrates partly inside the dense phase of the bed material and
thus increases solid material circulation and helps bed
temperature control.
By changing the ratio of primary and secondary air it is possible

to control the bed temperature and heat transfer inside the
furnace. The combustion air staging also reduces NOx -emission
level.

2.8 COMBUSTION AIR

Fluidizing air system
The fluidizing air is introduced by two parallel fans (2 x 60 %)

(283K005, 283K006) into the furnace (283E065) through air
nozzles penetrating the furnace floor. The purpose of fluidizing
air is to keep bed material in fluidized condition (in motion).
When bed material is cold (=during start-up) more air is required
to fluidize the bed compared to normal operation.

2.8 COMBUSTION AIR

Primary air pressure is controlled by inlet guide vanes of the fans

and air flows to two separately controlled windbox sections are
adjusted by control dampers. Fluidizing air amount depends on
fuel and boiler load so that
− high heating value fuel requires more fluidizing air than fuel
having lower heating value
− fluidizing air flow is increased when boiler load increases.
Boiler can be operated also with one fluidizing air fan but then
boiler load has to be limited to about 40 – 50 % of MCR load.
Primary air is preheated by low pressure steam in steam coil

preheater (283E078), when needed, before entering tubular flue
gas air preheater (283E069, 283E070).

2.8 COMBUSTION AIR

Secondary air system
Secondary air is used for air staging, which reduces NOx-

emissions and makes it possible to control the amount of
circulating bed material. The secondary air is fed into the furnace
by two parallel high pressure secondary air fans (2 x 60 %)
(283K007, 283K008). The secondary air pressure is controlled
by variable frequency drive of the fan and air flows to separate
sections are controlled by dampers.

2.8 COMBUSTION AIR

Both upper and lower secondary air levels are divided into two
separately controlled and measured sections. Additionally all
start-up burners (from 283E059 to 283E064) have own individual
air flow control and measuring devices.
Amount of secondary air is adjusted according to fuel and boiler

load and correction to air flow is made based on flue gas oxygen
measurement.
Secondary air is not preheated.
Air ducts
Air ducts are made of carbon steel. Hot duct surfaces are
insulated and suction ducts of the fans are equipped with
silencers (283E074, 283E075, 283E076, 283E077).
Ducting is equipped with necessary flow measurement devices,

shut-off dampers, control dampers and instrumentation to
enable practical operation of the boiler plant. Aerofoil-type
measurement devices (figure 1) are used for flow measurement
in bigger ducts and fluo seal air flows are measured by venturis.

2.8 COMBUSTION AIR

Figure 1 Aerofoil-type flow measurement device

2.8 COMBUSTION AIR

Fluo seal air system
Fluidizing air for loop seals (283E079, 283E080, 283E081) is

produced by two parallel roots type high pressure blowers
(283K009, 283K010). During the cold start-up the capacity of
both blowers is needed to fluidize the material in the loop seals
but in normal operation temperature only one blower is needed
and the other one can be stand-by. Air pressure is adjusted by
rotation speed of the blowers and air flow for each loop seal
section is adjusted by control dampers.

2.8 COMBUSTION AIR

Steam coil air preheater (283E078)
In steam coil preheater low pressure steam is used to heat

primary air before flue gas air preheater (283E069, 283E070).
Air temperature is increased to level, which keeps flue gas
preheater tube material temperature above acid dew point and
thus minimizes corrosion risk. In steam coil preheater low
pressure steam is led inside finned tubes where it condensates
and heats the air flowing through the heater.
Primary air temperature after the steam coil preheater is

adjusted according to flue gas temperature after the primary air
preheaters (283E069, 283E070). Primary air flue gas air
preheater has also material temperature measurements, which
can be monitored.
Condensate from steam air preheater is first led to condensate

tank (283T010) and then pumped to feed water tank (283T001).
The principle of the steam coil air prehaeater is shown in Figure

2.

2.8 COMBUSTION AIR

Figure 2 Principled drawing of steam coil air preheater
Flue gas air preheaters (for primary air) (283E069, 283E070)
Flue gas air preheater bundles are made of vertically arranged

plain tubes where air flows inside the tubes and flue gas outside
them. The flue gas air heater sections are located in the lower
part of the second pass and they are the last heat transfer
surfaces of the boiler.
The purpose of flue gas air preheater is to decrease flue gas

outlet temperature and thus increase boiler thermal efficiency. At
the same time it increases combustion air temperature, which
helps the combustion of wet fuels.

2.8 COMBUSTION AIR

2.8.3 Design criteria
Air fans are designed to produce adequate combustion air

amount at required pressure when fired specified fuels at boiler
design loads.
Ducting with accessories is dimensioned according to required

air flows and it is designed to sustain prevailing temperatures
and pressures in different parts of ducting.
Steam coil air preheater (283E078) is dimensioned to increase

combustion air temperature to required level to prevent acid dew
point corrosion risk.
Flue gas air preheaters (283E069, 283E070) are dimensioned so

that flue gas outlet temperature together with other heat surfaces
is decreased to about 145 °C at MCR load, when design coal is
fired.

2.8 COMBUSTION AIR

2.8.4 Equipment specification
2.8.4.1 Air fans
Primary (fluidizing) air fans

Equipment number 283K005 (1) and 283K006 (2)
Supplier Fläkt Woods Oy
Number of fans 2
Model HACB-125-244-cc-d-e
Type radial fan
Control inlet vane control
Bearings oil lubricated
Motor (supplied by RAPP) kW 1900
Performance at design point

Air flow / fan Nm3/s 73,4
Air flow / fan m3/s 85,1
Inlet density kg/m3 1,101
Total pressure rise Pa 17400
Inlet temperature °C 40
Fan efficiency % 83,3
Power demand / fan kW 1683
Figure 3 shows Primary air fan curve. Both of the fans are
equipped with an oil lubrication unit (figure 4).

2.8 COMBUSTION AIR

Figure 3 Primary Air Fan Curve

2.8 COMBUSTION AIR

Figure 4 Oil lubrication unit of the primary air fan

2.8 COMBUSTION AIR

Secondary air fans

Supplier Fläkt Woods Oy
Number of fans 2
Model HACB-112-177-cc-d-e
Type radial fan
Control (supplied by RAPP) variable frequency control
Motor (supplied by RAPP) kW 560
Performance at design point

Air flow /fan Nm3/s 35,3
Air flow / fan m3/s 40,9
Inlet density kg/m3 1,103
Total pressure rise Pa 9400
Inlet temperature °C 40
Fan efficiency % 85,2
Power demand /fan kW 437
Figure 5 shows Secondary air fan curve.

2.8 COMBUSTION AIR

Figure 5 Secondary Air Fan Curve

2.8 COMBUSTION AIR

Loopseal air blowers

Manufacturer Oy Ekstrom Flow Ab / Dresser
Number of blowers 2
Model XLP308
Type Three-bladed roots blower
Control variable frequency control
Motor size kW 250
Figure 6 Loop seal air blower (type XLP)

2.8 COMBUSTION AIR

Performance at maximum pressure difference

Differential pressure kPa 74,9
Air flow / blower Nm3/s 1,62
Temperature increase °C 83
Rotary blower speed rpm 2526
Accessories:
− pressure relief valves (2 pcs)
− acoustic enclosure (about 3m x 2m x 2,9m per one unit)
− suction side silencer (2 pcs)
− ventilation air fan for the acoustic enclosure (fan motor rated
power 0,55 kW – 0,75 kW, manufacturer WEG, CMG or equal)
− flexible connection (either a stainless steel bellows type with mild
steel flanges or a silicon tube type with mild steel flanges)
Figure 7 shows Loop seal air blower curve.

2.8 COMBUSTION AIR

PERFORMANCE BASED ON
DRESSER ROOTS AIR, INLET PRESSURE = 1013
HOLMES OPERATION PRESSURE PERFORMANCE MBAR INLET TEMPERATURE =
PO BOX B7 TURNBRIDGE FRAME XLP 308 20 0C
HUDDERSFIELD HD1 6RB MAX. PRESSURE RISE = 800 MBAR
MAX. SPEED = 2600 RPM
200 MBAR
8500.0 400 MBAR
600 MBAR
7500.0 800 MBAR
ACTUAL INLET FLOW - M3/H
6500.0
5500.0
4500.0
3500.0
2500.0
1500.0
500.0
500 1000 1500 2000 2500 3000
150.00
TEMP. RISE - 0C
100.00
800 MBAR
600 MBAR
50.00
400 MBAR
200 MBAR
0.00
500 1000 1500 2000 2500 3000
250.00
800 MBAR
200.00
POWER - KW
600 MBAR
150.00
400 MBAR
100.00
200 MBAR
50.00
0.00
500 1000 1500 2000 2500 3000
SPEED - RPM
Figure 7 Loop seal air blower curve

2.8 COMBUSTION AIR

2.8.4.2 Steam coil air preheater
Steam coil preheater for primary air

Equipment number 283E078
Manufacturer GEA HAPPEL GmbH & CoKG
Number of preheaters pcs 1
Number of fin tubes pcs 4 x 156
Fin pitch mm 4
Fin tube material St 37.0 zinc coated
MCR (100%) Design

Air
− flow Nm3/s 119,6 125,6
− temperature in °C 44 34
− temperature out °C 82 90
− pressure drop Pa about 300 350
Low pressure steam

− flow kg/s 2,72 4,21
− pressure barg 2,2 2,3
− temperature in °C 150 150
− temperature out °C 136 136
Heat effect kW 5944 9197
Mechanical design pressure bar(g) 6

Mechanical design temperature °C 250

2.8 COMBUSTION AIR

2.8.4.3 Flue gas air preheaters
Primary air flue gas air preheater 1

Tube material S235JRG2 (Fe 37B)
Manufacturer Evire Metalli Oy (Kvaerner design)
Type tubular air preheater with horizontal plain tubes
Number of tube bundles pcs 1
Tube OD mm 48,3
Tube wall thickness mm 4,0
Number of tubes pcs 4686
Tube back spacing
− two uppermost rows mm 100
− other rows mm 75
Tube side spacing mm 75
2
Heat transfer surface m 4266
Lowest tube row is equipped with five tube material temperature

measurements.
Cold end tubes of preheater package are equipped with protection

tubes (figure 8) to minimize corrosion risk.
− protection tube material S235JRG2 (Fe 37B)
− protection tube OD mm 55,0
− protection tube wall thickness mm 2,0

2.8 COMBUSTION AIR

Primary air flue gas air preheater 2

Tube material S235JRG2 (Fe 37B)
Manufacturer Evire Metalli Oy (Kvaerner design)
Type tubular air preheater with horizontal plain tubes
Number of tube bundles pcs 1
Tube OD mm 48,3
Tube wall thickness mm 2,9
Number of tubes pcs 4686
Tube back spacing
− two uppermost rows mm 100
− other rows mm 75
Tube side spacing mm 75
Heat transfer surface m2 4266
Gas tight
Protection tube
Gas tight
Ø 54x2,0
Air heater tube

Insulation
400
Figure 8 Protection tube principle

2.8 COMBUSTION AIR

2.8.4.4 Air nozzles
Primary air nozzles

Type “CFB” cast nozzle
Manufacturer Keycast
Number of nozzles pcs 2643
Holes/nozzle pcs 12
Diameter of holes mm 11
Nozzle spacing mm 155/185 x 200
Flow, MCR 100% Nm3/s 122,4

Temperature °C 140
Pressure loss kPa 4,1
Secondary air nozzles
Lower secondary air openings

Material AVESTA 253 MA
Number of openings
− front wall pcs 12
− rear wall pcs 12
Diameter of openigs mm 219,1
Height from furnace bottom mm 1500
Nozzles inclined 30° downwards

2.8 COMBUSTION AIR

Upper secondary air openings

Material AVESTA 253 MA
Number of openings
− front wall pcs 6+8
− rear wall pcs 6+9
Diameter of openings mm 219,1 or 168,3
Height from furnace bottom mm 3700
Nozzles inclined 30° downwards
Fluoseal fluidizing air nozzles
Downleg
Type “CFB”
Material AISI 304 L
Number of nozzles / pcs 35
cyclone
Holes/nozzle pcs 7
Diameter of holes mm 3,9
MCR Start-up
3
Flow, design / cyclone Nm /s 0,17 0,43
Temperature °C 85 123
Pressure loss kPa 4,95 26,8

2.8 COMBUSTION AIR

Upleg
Type “CFB”
Material AISI 304 L
Number of nozzles / pcs 36
cyclone
Holes/nozzle pcs 9
Diameter of holes mm 3,9
MCR Start-up
3
Flow, design /cyclone Nm /s 0,23 0,65
Temperature °C 85 123
Pressure loss kPa 5,2 33,9

2.8 Combustion Air System

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Asiakirjan nimi - Name of Document Tunniste - Identification Rev.

PROCESS DESCRIPTION CFBT-582-1 1

Osasto - Department Kohde - Subject Sivu - Page

Power Generation RAPP PB3 PROJECT 1 (26)