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Operating Experience of CFB Boiler Burning Lignite with High Shrinkage Ash
Property

Conference Paper · June 2015

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 Operating Experience of CFB Boiler Burning Lignite with High Shrinkage Ash
Property
1 2 3 4 5
V.Vidya , M.Lakshminarasimhan , B.Ravikumar , S.V.Srinivasan , A.Lawrence
1,2,3,4,5
Bharat Heavy Electricals Limited(BHEL), Tiruchirapalli, India
1
vidya@bheltry.co.in

Abstract
Two Circulating Fluidized Bed boilers of rating 125 MWe (100% load) were installed for burning lignite
from the mines located at Barsingsar, Rajasthan in India. The fuel characteristics obtained by
analyzing bore hole samples and subsequent combustion of lignite from mines in the CFB test facility
at Bharat Heavy Electricals Limited premises in Tiruchirapalli were used for initial design of the boiler.
Test results indicated no peculiar behavior of lignite ash. However, during initial operation of boiler
beyond 30% load, circulating material agglomerated in the primary loop components, thereby
preventing load raising. Repeated occurrences of material agglomeration were observed in
subsequent operations. Analysis of the deposits indicated that the ash exhibited high shrinkage
followed by formation of sinters. This paper describes the summary of operational issues faced,
investigation carried out and successful establishment of operating regime in overcoming the difficult
characteristics of the fuel used in the boiler.
Keywords: Lignite, Circulating fluidized bed boiler, agglomeration

1. Introduction
Coal reserves in India are one of the largest in the world. As of 2012, India had 293.5 billion metric
tons of the resource with majority of the reserves belonging to the Gondwana type. Although, coal
contributes over 53% of the primary energy consumption with around 65% of the power plants coal
driven, energy demand in the country escalates at a rate surpassing the coal production rate. In view
of meeting the energy requirement of the nation alternate fossil fuel resources locally available are
gaining significance in the energy market.
Lignite reserves in the country are being exploited for electricity generation. Proven lignite reserves
surmount to about 4177 million metric tons. The production of lignite in 2011 was about 37.73 million
metric tons which was higher in comparison to the previous year by 10.7%. Lignite deposits occur in
Tamil Nadu, Gujarat, Rajasthan, Kerala, Puducherry, Jammu & Kashmir in India. Lignite derived from
Barsingsar mines at Rajasthan constitutes varying ash content (8-30% by weight), sulphur content of
about 0.2-3.8%, moisture of about 32-45% by weight and higher heating value in the range 1900-
3300 kcal/kg. Circulating fluidized bed combustion (CFBC) technology with in-furnace SOx capture is
highly suitable for firing this lignite with significantly low heating value and high percentage of sulphur.
With experience gained from successfully operating lignite based 125 MWe plants at Surat in Gujarat,
Bharat Heavy Electricals Limited (BHEL) had supplied 2x125 MWe CFB power plants at Barsingsar,
Rajasthan for burning lignite with the characteristics mentioned above. Herein is described the design
of the CFB boilers installed at Barsingsar, problems occurred during operation and resolution
provided for achieving full load.

2. Barsingsar lignite CFB Boiler design

Bore hole samples of lignite were extracted for determining fuel composition and ash deformation
temperature for arriving at basic design parameters. Fuel samples prepared in accordance with
ASTM-D 2013 were analyzed at laboratory in BHEL, Tiruchirapalli (Trichy) premises. Ash fusibility
tests carried out as per ASTM D-1857 indicated the initial deformation temperature to be 1320°C.
Subsequently, 100 metric tons of lignite was extracted from the mines and elaborate tests with regard
to combustion and ash deformation were carried out at Trichy lab facility. The test results of bore hole
samples and mines fuel are shown in Table.1. Shrinkage tests performed using thermo mechanical

135
analyzer and heating microscope indicated that about 8% shrinkage occurred between 900°C and
1000°C (operating regime of CFBC boiler). Smooth material circulation and efficient combustion of
lignite was observed in CFBC pilot plant in the temperature range 850°C-950°C. Based on the test
results, boiler was designed for the steam parameters and fuel analysis indicated in table 2.
Table1. Lignite composition

Proximate Analysis (as fired)

Parameter Unit Bore hole Mines
sample Lignite
Total Moisture %wt 13.9 17.3
Volatile Matter %wt 39.8 30. 9
Ash %wt 10.9 25.4
Fixed Carbon %wt 35.4 26.4
Ultimate Analysis
Carbon %wt 52.9 39.7
Hydrogen %wt 4.1 3.2
Nitrogen %wt 0.7 0.9
Sulphur %wt 1.0 0.3
Oxygen %wt 16.5 13.2
HHV (kcal/kg) 5096 3803
Chemical composition of ash
Na2O %wt 2.4 2.4
MgO %wt 2.5 0.6
K2O %wt 0.1 0.4
Al2O3 %wt 36.9 7.8
SiO2 %wt 45.4 67.8
TiO2 %wt 0.5 0.7
Fe2O3 %wt 0.8 4.7
P2O5 %wt -- --
SO3 %wt -- --
CaO %wt -- 13.8
Initial
deformation
temperature °C 1320 >1400

Table 2. CFB boiler parameters & Tender fuel specification

Parameters Unit Design Proximate Analysis (as fired) Ash analysis

Main steam Parameter Unit Data Parameter %wt
Flow kg/s 112.5 Total Moisture %wt 39.1 Na2O 1.2
Pressure bar 128.5 Volatile Matter %wt 18.3 MgO 1.7
Temperature °C 540 Ash %wt 26.1 K2O 0.6
Reheat steam Fixed Carbon %wt 16.5 Al2O3 29.2
Flow kg/s 93.3 Ultimate Analysis SiO2 48.7
Outlet pressure bar 30.5 Carbon %wt 26.3 TiO2 1.9
Outlet °C 540 Hydrogen %wt 1.9 Fe2O3 4.3
temperature
Feed water Nitrogen %wt 0.5 P2O5 0.2
Temperature °C 236.8 Sulphur %wt 0.8 SO3 4.0
Oxygen %wt 5.3 CaO --
HHV (kcal/kg) 2600

A typical sketch of the primary loop of the boiler is indicated in figure1. The circulating loop of the
boiler includes a furnace, two cyclones located on either side, two loop seals and four external

136
fluidized bed heat exchangers for capturing evaporative, superheat and reheat duty, integrated with
the furnace walls.

Figure 1. CFB loop of the boiler

3. Issues faced while commissioning

During initial operation of boiler beyond 30% load with lignite feeding, pressure increase above design
value at either cyclone to seal pot standpipe, decrease in seal pot blower pressure and a
corresponding decrease in inventory of ash (differential pressure – (dp)) in the combustor was
observed. Eventually the boiler tripped on account of combustor dp dropping below the minimum
required value. On inspecting the primary loop, it was found that circulating material had
agglomerated in standpipe of cyclone to loop seal as indicated in figure 2. The agglomerated
materials were loosely bonded and with application of little force, the agglomerated material crumbled
(figure 3a & 3b). Pressure rise in the standpipe occurred again in the subsequent restart of boiler
when escalating beyond 30% load with lignite firing. With sustained lignite feeding, agglomeration of
circulating material enhanced, enveloping the entire loop seal thereby depleting bed material in
combustor drastically (indicated by low pressure readings at seal pot blower outlet and combustor)
leading to unit trip.

Figure 2. Circulating material agglomeration in cyclone to seal pot standpipe

137
Figure 3a. Lump formed in cyclone Figure 3b. Lump broken to smaller pieces
by crushing with hand
Henceforth, in the operation trials that followed, whenever pressure in the standpipe increased to a
critical value, the fuel feeding alone was cut off, meanwhile the material accumulation collapsed itself
and fuel feeding was resumed when the pressure values dropped below the critical value. Either of
the two cyclones were getting choked repeatedly at random loads (at about 30%, 70% and 90% of
maximum load). The pressure fluctuations recorded at site, at 74% load, is represented in figure 4.

Figure 4. Pressure fluctuations reported at site at 74% load.

From figure it can be seen that on shutting off fuel feeding when pressure at standpipe escalated to
trip value, pressure raised at a faster rate and gradually decreased without any external force. Fuel
feeding was resumed when the pressure reached near design value.
Furthermore, during this instance, the combustor dp reduced when standpipe pressure increased and
returned to design value with standpipe pressure reattaining base value. The same trend was
observed at seal pot blower outlet indicating simultaneous material depletion in seal pot, combustor
zone and inventory build-up in standpipe. Therefore, full load could not be achieved due to repeated
occurrences of cyclone choking.

138
4. Analysis and discussion
Agglomerated material from cyclone - standpipe, lignite samples fired corresponding to various
instances of choking observed in boiler, lignite sieve analysis and boiler operating parameters were
collected for analysis. Extensive tests with regard to composition and ash sintering (welding of
particles below its melting point) were carried out at Trichy. Ash percentage in fuels, calorific value of
the different samples collected are compared with tender values in table 3. For sintering and ash
fusion measurement, truncated cone shaped ash pellets were prepared by uni-axial pressing of ash
powder in a die without any binder. The pellets after being air dried were introduced at ambient
temperature into furnace of heating microscope. The furnace was heated to 1000°C at a constant
heating rate of 10°C per minute and then heated to 1400°C at 8°C per minute. The shrinkage test
results revealed that the lignite ash shrunk after 860°C. Sample A shrunk at a rapid rate in the
temperature range 860°C – 960°C followed by sintering. The rate of shrinkage of area with respect to
corresponding change in temperature i.e. dA/100A 0 dT, where dA-difference in area, A 0 -initial area
and dT-difference in temperature is indicated in figure 5 for the temperature range 820°C-1000°C for
sample A. Maximum rate of shrinkage of 0.8% /ºC occurred at about 900°C.
Table 3. Ash % & Calorific values of samples tested

Unit Tender A B C D

Ash % 26.11 24.6 10.93 25.43 36.30

HHV kcal/kg 2600 4549 5096 3803 2974

Figure 5. Sample A - Shrinkage Rate over temperature

The major constituents of ash were oxides of aluminum and silica. The intensity of sintering (defined
by maximum rate of shrinkage of ash pellet with temperature [1]) with respect to silica, alumina
constituents determined in the laboratory tests is compared in table 4.

Table 4. Sintering potential Vs SiO 2 -Al 2 O 3

Sample SiO /Al O Ratio % SiO + %Al O Sintering Tendency

2 2 3 2 2 3

Tender 1.67 77.94 Low

A 1.12 82.8 High
B 1.23 82.3 High
C 8.69 75.6 Low
D 1.45 82.2 Medium

139
The following was concluded from the internal analysis carried out at Trichy.
1. Lignite exhibited unique ash shrinkage behaviour at about 860°C followed by sintering of the
material.
2. The sintering extent varied for the fuel samples (though extracted from the same mines).
3. The rate of sintering reduced with increase in ashing temperature.[1]
Lignite analysis were independently verified at Abo Akademi, Finland by Prof.Hupa and his team and
summarised that
1. Lignite ash starting shrinking at about 860°C.
2. High sintering was noticed during compression strength tests in case of lignite ash at 900°C
whereas cyclone deposit did not undergo any sintering during compression test, however 30
% by weight lignite ash addition to the cyclone deposit resulted in formation of hard sinters at
900°C.
3. Sintering of cyclone deposit and lignite ash mixture was not mitigated by limestone addition
during compression strength test.
Phenomenon described in point 2 above was also observed in site operation that cutting off the fuel
feed during the choking instance cleared the situation as the temperature dropped below 850ºC.
Furthermore, the fuel fed at site had finer constituents. The amount of material below 1 mm, was 40%
higher than the recommended value. Therefore, the temperature at cyclone-seal pot region increased
to 860°C resulting in ash sintering at low loads, about 30% load itself, due to post combustion of fines
carried to the cyclone separator while the combustor temperature was only about 800°C.

5. Resolution provided
The elaborate tests carried out clearly indicated that the ash material did not sinter further, once
sintered (point 2 of the result provided by Abo Akademi, Finland). Based on this observation, full load
was attained by modifying the process parameters to achieve “dead burning of the ash” in the
combustor itself as the larger volume of furnace and fluidizing atmosphere prevent material
agglomeration. Thus material agglomeration in cyclone-standpipe was prevented by raising furnace
temperature to about 900°C as against 850°C considered during design. The mentioned temperature
modification beyond 25% load was achieved by-
1. Adjusting primary and secondary air flow
2. Varying combustor inventory to achieve higher bottom temperature
5.1 Description of process modification
Above25% load, with lignite feeding, the combustor inventory was maintained at lower level than
design while correspondingly admitting lesser primary air through grate than the original design value
for the same load and injecting the rest as secondary air. This resulted in bed temperatures of about
900°C and the temperature at combustor top was in the range 730-790°C. Consequently, the seal pot
temperatures were lesser than 860°C at low loads. Up to 40% load, fluidization of solids inventory
was maintained in the stationary bubbling bed regime by suitably reducing primary air to reduce
circulation of fines/post combustion. Further load increase was attained by increasing primary air to
operate in circulating regime, however the injected primary air was lower than the design value so as
to restrict the quantity of fines carried to the cyclone in view of limiting temperature pick up due to post
combustion and also to maintain bed temperature >880°C. A comparison of combustor temperatures
observed at site during initial operation with design dp, primary air flow values and trials after
parameters modification is represented in figure 6. The primary air was maintained lower than design
values until about 50% load. Beyond this, till full load, the primary air was increased to the original
design values and simultaneously the inventory was gradually increased to the design value. Figures
7a and 7b indicate the design dp and level of inventory reduced from design during revised operation
for the various loads. For the cases above 50%load, furnace temperature could be maintained in
880°C-900°C range by adjustment of ash flow to the external FBHEs- a unique feature with BHEL
CFB Technology . With the revised process parameters, cyclone choking was prevented. Combustor
temperatures and standpipe pressure after process modification observed at site is represented in
figure 8. It can be seen that the pressures at standpipe were very near the design pressure indicating
smooth circulation of solid materials. Therefore, full load was successfully demonstrated.

140
 Figure 6. Comparison of bed temperatures at site before and after process parameters
modification

Figure 7a. Design inventory in combustor for the various loads

Figure 7b. Modification of combustor dp from design to achieve higher bed temperatures

141
 Figure 8. Bed temperatures and standpipe pressures observed at site when raising load to full
capacity

6. Conclusion
As observed from ash tests, the mineralogy of the lignite exhibits varying sintering behaviour for
different ash composition although extracted from the same mines. CFB combustion has been proven
to be the ideal technology for firing lignite with high ash shrinkage property. Rated full load capacity of
125 MWe was successfully demonstrated at site. Successful firing of this kind of fuel with unique ash
sintering phenomena is a breakthrough in lignite driven power plants in India and is likely to promote
more lignite based power plants in the country.

Acknowledgements
Bharat Heavy Electricals Limited, India thank Professor Hupa and his team- Patrik Yrjas, Patrycja
Piotrowska & Tor Laurén, Abo Akademi, Finland for their important finding from the analysis that the
ash did not sinter any further once sintered, which kindled the thought process of modifying process
parameters to overcome the choking issue and achieve full load.

References
[1] Selvakumaran P, Lawrence A, Lakshminarasimhan M and Bakthavatsalam AK: Mineralogical
influence of mining intrusions in CFB combustion of Indian Lignite. International Journal of Energy &
Environmental Engineering 2013, 4:34.

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