CFB Boiler Design, Operation and Maintenance

CFB Boiler Design, Operation and
Maintenance
By Pichai Chaibamrung
1
Content Day1
1. Introduction to CFB
2. Hydrodynamic of CFB
3. Combustion in CFB
4. Heat Transfer in CFB
5. Basic design of CFB
6. Operation
7. Maintenance
8. Basic Boiler Safety
9. Basic CFB control
2
Objective
— To understand the typical arrangement in CFB
— To understand the basic hydrodynamic of CFB
— To understand the basic combustion in CFB
— To understand the basic heat transfer in CFB
— To understand basic design of CFB
— To understand theory of cyclone separator
Know Principle Solve Everything
3
1. Introduction to CFB
1.1 Development of CFB
1.2 Typical equipment of CFB
1.3 Advantage of CFB
4
1.1 Development of CFB
— 1921, Fritz Winkler, Germany, Coal Gasification
— 1938, Waren Lewis and Edwin Gilliland, USA, Fluid Catalytic Cracking,
Fast Fluidized Bed
— 1960, Douglas Elliott, England, Coal Combustion, BFB
— 1960s, Ahlstrom Group, Finland, First commercial CFB boiler, 15
MWth, Peat
5
1.2 Typical Component of CFB Boiler
6
Wind box and grid nozzle
primary air is fed into wind box.
Air is equally distributed on
furnace cross section by passing
through the grid nozzle. This will
help mixing of air and fuel for
completed combustion
7
Bottom ash drain
coarse size of ash that is not
take away from furnace by
fluidizing air will be drain
at bottom ash drain port
locating on grid nozzle
floor by gravity.
bottom ash will be cooled
and conveyed to silo by
cooling conveyor.
8
HP Blower
supply high pressure air to
fluidize bed material in loop
seal so that it can overflow to
furnace
Rotameter
Supplying of HP
blower to loop seal 9
Cyclone separator
located after furnace exit and
before convective part.
use to provide circulation by
trapping coarse particle back to
the furnace
Fluidized boiler without this
would be BFB not CFB
10
Evaporative or Superheat Wing Wall
located on upper zone of furnace
it can be both of evaporative or SH
panel
lower portion covered by erosion
resistant materials
11
Fuel Feeding system
solid fuel is fed into the lower
zone of furnace through the
screw conveyor cooling with
combustion air. Number of
feeding port depend on the
size of boiler
12
Refractory
refractory is used to protect
the pressure part from
serious erosion zone such as
lower bed, cyclone separator
13
Solid recycle system (Loop seal)
loop seal is located between
dip leg of separator and
furnace. Its design physical is
similar to furnace which have
air box and nozzle to
distribute air. Distributed air
from HP blower initiate
fluidization. Solid behave like
a fluid then over flow back to
the furnace.
14
Kick out
kick out is referred to
interface zone between
the end of lower zone
refractory and water tube.
It is design to protect the
erosion by by-passing the
interface from falling
down bed materials
15
Lime stone and sand system
lime stone is pneumatically feed or gravitational feed into
the furnace slightly above fuel feed port. the objective is to
reduce SOx emission.
Sand is normally fed by gravitation from silo in order to
maintain bed pressure. Its flow control by speed of rotary
screw.
16
1.2 Typical Arrangement of CFB Boiler
17
1.3 Advantage of CFB Boiler
— Fuel Flexibility
18
1.3 Advantage of CFB Boiler
— High Combustion Efficiency
- Good solid mixing
- Low unburned loss by cyclone, fly ash recirculation
- Long combustion zone
— In situ sulfur removal
— Low nitrogen oxide emission
19
2. Hydrodynamic in CFB
2.1 Regimes of Fluidization
2.2 Fast Fluidized Bed
2.3 Hydrodynamic Regimes in CFB
2.4 Hydrodynamic Structure of Fast Beds
20
— Fluidization is defined as the operation through which fine
solid are transformed into a fluid like state through
contact with a gas or liquid.
21
— Particle Classification
Distribution Size (micron)

CFB1 CFB2 BFB
100% <600 <1000 <1680
75% <250 <550 <1190
50% <180 <450 <840
25% <130 <250 <590
100% >100 >420
22
— Particle Classification
23
— Comparison of Principal Gas-Solid Contacting Processes
24
— Packed Bed
The pressure drop per unit height of a packed beds of a uniformly size
particles is correlated as (Ergun,1952)
Where U is gas flow rate per unit cross section of the bed called
Superficial Gas Velocity
25
— Bubbling Fluidization Beds
Minimum fluidization velocity is velocity where the fluid
drag is equal to a particle’s weight less its buoyancy.
26
— Bubbling Fluidization Beds
For B and D particle, the bubble is started when superficial
gas is higher than minimum fluidization velocity
But for group A particle the bubble is started when
superficial velocity is higher than minimum bubbling
velocity
27
— Turbulent Beds
when the superficial is continually increased through a
bubbling fluidization bed, the bed start expanding, then
the new regime called turbulent bed is started.
28
29
— Terminal Velocity
Terminal velocity is the particle velocity when the

forces acting on particle is equilibrium
30
— Freeboard and Furnace Height
- considered for design heating-surface area
- considered for design furnace height
- to minimize unburned carbon in bubbling
bed
- the freeboard heights should be exceed or
closed to the transport disengaging heights
31
2.2 Fast Fluidization
— Definition
32
2.2 Fast Fluidization
— Characteristics of Fast Beds
- non-uniform suspension of slender particle agglomerates or clusters moving
up and down in a dilute
- excellent mixing are major characteristic
- low feed rate, particles are uniformly dispersed in gas stream
- high feed rate, particles enter the wake of the other, fluid drag on the leading
particle decrease, fall under the gravity until it drops on to trailing particle
33
2.3 Hydrodynamic regimes in a CFB
Cyclone Separator :
Swirl Flow
Back Pass:
Pneumatic Transport
Furnace Upper SA:

Fast Fluidized Bed
Lower Furnace below SA:
Turbulent or bubbling
fluidized bed
Return leg and lift leg :

Pack bed and Bubbling Bed
34
— Axial Voidage Profile
Secondary air is fed
Bed Density Profile of 135 MWe CFB Boiler (Zhang et al., 2005)
35
— Velocity Profile in Fast Fluidized Bed
36
— Velocity Profile in Fast Fluidized Bed
37
— Particle Distribution Profile in Fast Fluidized Bed
38
39
Effect of SA injection on particle
distribution by M.Koksal and
F.Hamdullahpur (2004). The
experimental CFB is pilot scale CFB.
There are three orientations of SA
injection; radial, tangential, and mixed
40
Increasing solid circulation
Increasing SA to 40%
rate effect to both
does not significant on
lower and upper zone
suspension density above
of SA injection point
SA injection point
which both zone is
but the low zone is
denser than low
denser than low SA ratio
solid circulation rate
No SA, the suspension With SA 20% of PA,

density is proportional the solid particle is hold up
l to solid circulation rate when compare to no SA
41
— Effects of Circulation Rate on Voidage Profile
higher solid recirculation rate
42
— Effects of Circulation Rate on Voidage Profile
Pressure drop across the L-valve is

proportional to solid recirculation rate
higher solid recirculation rate
43
— Effect of Particle Size on Suspension Density Profile
- Fine particle - - > higher suspension density
- Higher suspension density - - > higher heat transfer
- Higher suspension density - - > lower bed temperature
44
— Core-Annulus Model
- the furnace may be spilt into two zones : core and
annulus
core
Core
- Velocity is above superficial velocity
annulus
- Solid move upward
Annulus
- Velocity is low to negative
- Solids move downward
45
— Core-Annulus Model
core
annulus
46
— Core Annulus Model
- the up-and-down movement solids in the core and
annulus sets up an internal circulation
- the uniform bed temperature is a direct result of internal
circulation
47
3. Combustion in CFB
3.1 Coal properties for CFB boiler
3.2 Stage of Combustion
3.3 Factor Affecting Combustion Efficiency
3.4 Combustion in CFB
3.5 Biomass Combustion
48
3.1 Coal properties for CFB Boiler
Properties
- coarse size coal shall be crushed by coal crusher
- sizing is an importance parameter for CFB boiler improper size might
result in combustion loss
- normal size shall be < 8 mm
49
A particle of solid fuel is injected into an FB undergoes the
following sequence of events:
- Heating and drying
- Devolatilization and volatile combustion
- Swelling and primary fragmentation (for some types of coal)
- Combustion of char with secondary fragmentation and attrition
50
3.2 Stages of Combustion
— Heating and Drying
- Combustible materials constitutes around 0.5-5.0% by
weight
of total solids in combustor
- Rate of heating 100 °C/sec – 1000 °C/sec
- Heat transfer to a fuel particle (Halder 1989)
51
Devolatilization and volatile combustion
- first steady release 500-600 C
- second release 800-1000C
- slowest species is CO (Keairns et al., 1984)
- 3 mm coal take 14 sec to devolatilze
at 850 C (Basu and Fraser, 1991)
52
— Char Combustion
2 step of char combustion
1. transportation of oxygen to carbon surface
2. Reaction of carbon with oxygen on the carbon surface
3 regimes of char combustion
- Regime I: mass transfer is higher than kinetic rate
- Regime II: mass transfer is comparable to kinetic rate
- Regime III: mass transfer is very slow compared to kinetic rate
53
— Communition Phenomena During Combustion
Attrition, Fine particles from
Volatile release in non-porous coarse particles through
particle cause the high mechanical contract like
internal pressure result in abrasion with other particles
break a coal particle into
fragmentation
Char burn under regime I

which is mass transfer is
higher than kinetic trasfer.
The sudden collapse or other
Volatile release cause the type of second fragmentation
particle swell call percolative fragmentation
occurs
Char burn under regime I, II,

the pores increases in size à
weak bridge connection of
carbon until it can’t withstand
the hydrodynamic force. It will
fragment again call “
secondary fragmentation”
54
— Fuel Characteristics
the lower ratio of FC/VM result in higher combustion
efficiency (Makansi, 1990), (Yoshioka and Ikeda,1990),
(Oka, 2004) but the improper mixing could result in lower
combustion efficiency due to prompting escape of volatile
gas from furnace.
55
— Operating condition (Bed Temperature)
- higher combustion temperature --- > high combustion
efficiency Limit of Bed temp
-Sulfur capture
-Bed melting
-Water tube failure
High combustion temperature result in high

oxidation reaction, then burn out time
decrease. So the combustion efficiency
increase. 56
— Fuel Characteristic (Particle size)
-The effect of this particle size is not clear

-Fine particle, low burn out time but the
probability to be dispersed from cyclone
the high
-Coarse size, need long time to burn out.
-Both increases and decreases are
possible when particle size decrease
57
— Operating condition (superficial velocity)
- high fluidizing velocity decrease combustion efficiency because
Increasing probability of small char particle be elutriated from
circulation loop
- low fluidizing velocity cause defluidization, hot spot and sintering
58
— Operating condition (excess air)
- combustion efficiency improve which excess air < 20%
Combustion loss
decrease
significantly when
excess air < 20%.
Excess air >20% less
significant improve
combustion efficiency.
59
Operating Condition
The highest loss of combustion result from elutriation of char particle
from circulation loop. Especially, low reactive coal size smaller than 1
mm it can not achieve complete combustion efficiency with out fly
ash recirculation system.
However, the significant efficiency improve is in range 0.0-2.0 fly ash
recirculation ratio.
60
3.4 Combustion in CFB Boiler
— Lower Zone Properties
- This zone is fluidized by primary air constituting about
40-80% of total air.
- This zone receives fresh coal from coal feeder and
unburned coal from cyclone though return valve
- Oxygen deficient zone, lined with refractory to protect
corrosion
- Denser than upper zone
61
— Upper Zone Properties
- Secondary is added at interface between lower and upper
zone
- Oxygen-rich zone
- Most of char combustion occurs
- Char particle could make many trips around the furnace
before they are finally entrained out through the top of
furnace
62
— Cyclone Zone Properties
- Normally, the combustion is small when compare to in
furnace
- Some boiler may experience the strong combustion in
this zone which can be observe by rising temperature in
the cyclone exit and loop seal
63
— Fuel Characteristics
- high volatile content (60-80%)
- high alkali content à sintering, slagging, and fouling
- high chlorine content à corrosion
64
— Agglomeration
SiO2 melts at 1450 C
Eutectic Mixture melts at 874 C
Sintering tendency of fuel is indicated by the following

(Hulkkonen et al., 2003)
65
Options for Avoiding the Agglomeration Problem
- Use of additives
- china clay, dolomite, kaolin soil
- Preprocessing of fuels
- water leaching
- Use of alternative bed materials
- dolomite, magnesite, and alumina
- Reduction in bed temperature
66
— Agglomeration
67
— Fouling
- is sticky deposition of ash due to evaporation of alkali salt
- result in low heat transfer to tube
68
— Corrosion Potential in Biomass Firing
- hot corrosion
- chlorine reacts with alkali metal à from low
temperature melting alkali chlorides
- reduce heat transfer and causing high temperature
corrosion
69
4. Heat Transfer in CFB
4.1 Gas to Particle Heat Transfer
4.2 Heat Transfer in CFB
70
4.1 Gas to Particle Heat Transfer
— Mechanism of Heat Transfer
In a CFB boiler, fine solid particles

agglomerate and form clusters or
stand in a continuum of generally
up-flowing gas containing sparsely
dispersed solids. The continuum is
called the dispersed phase, while
the agglomerates are called the
cluster phase.
The heat transfer to furnace wall
occurs through conduction from
particle clusters, convection from
dispersed phase, and radiation
from both phase.
71
4.1 Heat Transfer in CFB Boiler
— Effect of Suspension Density and particle size
Heat transfer coefficient is proportional to the square root of suspension density
72
— Effect of Fluidization Velocity
No effect from fluidization velocity when leave the suspension density constant
73
74
75
— Effect of Vertical Length of Heat Transfer Surface
76
— Effect of Bed Temperature
77
— Heat Flux on 300 MW CFB Boiler (Z. Man, et. al)
78
— Heat transfer to the walls of commercial-size
Low suspension density low

heat transfer to the wall.
79
— Circumferential Distribution of Heat Transfer Coefficient
80
5 Design of CFB Boiler
— 5.1 Design and Required Data
— 5.2 Combustion Calculation
— 5.3 Heat and Mass Balance
— 5.4 Furnace Design
— 5.5 Cyclone Separator
81
5.1 Design and Required Data
The design and required data normally will be specify by owner
or client. The basic design data and required data are;
Design Data :
- Fuel ultimate analysis - Weather condition
- Feed water quality - Feed water properties
Required Data :
- Main steam properties - Flue gas temperature
- Flue gas emission - Boiler efficiency
82
5.2 Combustion Calculation
— Base on the design and required data the following data
can be calculated in this stage :
- Fuel flow rate - Combustion air flow rate
- Fan capacity - Fuel and ash handling capacity
- Sorbent flow rate
83
5.3 Heat and Mass Balance
Main steam
Heat input
Radiation
Heat output
Feed water
Blow down
Flue gas
Moisture in fuel Unburned in fly ash

and sorbent
Fuel and
sorbent
Combustion air
Unburned in Moisture in
bottom ash combustion air
84
5.3 Heat and Mass Balance
— Mass Balance Mass input
Mass output
SolidSolid
Fluein
gas
Make up Flue gas
bed material
Fuel and
sorbent
Moisture in fuel fly ash

and sorbent
Fuel and
sorbent
Make up
bed material
fly ash
bottom ash
bottom ash
85
5.4 Furnace Design
— The furnace design include: 1. Furnace cross section
1. Furnace cross section Criteria
2. Furnace height - moisture in fuel
3. Furnace opening - ash in fuel
- fluidization velocity
- SA penetration
- maintain fluidization in lower
zone at part load
86
5.4 Furnace Design
2. Furnace height 3. Furnace opening
Criteria Criteria
- Heating surface - Fuel feed ports
- Residual time for sulfur - Sorbent feed ports
capture - Bed drain ports
- Furnace exit section
87
5.5 Cyclone Separator
— 6.1 Theory
— 6.2 Critical size of particle
88
— The centrifugal force on the particle entering the cyclone
is
— The drag force on the particle can be written as
— Under steady state drag force = centrifugal force
89
— Vr can be considered as index of cyclone efficiency, from

above equation the cyclone efficiency will increase for :
- Higher entry velocity

- Large size of solid
- Higher density of particle
- Small radius of cyclone
- low value of viscosity of gas
90
— The particle with a diameter larger than theoretical cut-
size of cyclone will be collected or trapped by cyclone
while the small size will be entrained or leave a cyclone
— Actual operation, the cut-off size diameter will be defined

as d50 that mean 50% of the particle which have a
diameter more than d50 will be collected or captured.
91
6. Operation
92
Content
6.1 Before start
6.2 Grid pressure drop test
6.3 Cold Start
6.4 Normal Operation
6.5 Normal Shutdown
6.6 Hot Shutdown
6.7 Hot Restart
6.8 Malfunction and Emergency
93
6.1 Before Start
— all maintenance work have been completely done
— All function test have been checked
— cooling water system is operating
— compressed air system is operating
— Make up water system
— Deaerator system
— Boiler feed water pump
— Condensate system
— Oil and gas system
— Drain and vent valves
— Air duct, flue gas duct system
94
6.1 Before Start
— Blow down system
— Sand feeding system
— Lime stone feeding system
— Solid fuel system
— Ash drainage system
— Control and safety interlock system
95
6.2 Grid Pressure Drop Test
— For check blockage of grid
nozzle
— Furnace set point = 0
— Test at every PA. load
Pf= 0
— Compare to clean data or design
data
— Shall not exceed 10% from
design data
— Perform in cold condition
Pb
Pw
FI
96
6.3 Cold Start
-100 mm normal level
Fill boiler Start Fan
ID,HP,SA,PA
Boiler Interlock Purge

300 S
Low level cut off

Start up Burner Boiler Warm Up
Tb 150-200 C
30-50 mbar, Tb 550-600 C

Feed Bed Material Feed Solid Fuel
Raise to MCR
97
Fill Boiler
-Close all water side drain valve
-Open all air vent valve at drum and
superheat
-Open start up vent valve 10-15%
-Slowly feed water to drum until level 1/3 of
sigh glass
98
Start Fan
1.Start ID.Fan
2.Start HP Blower 4.Start PA.Fan
3.Start SA.Fan
99
Boiler Interlock
Emergency stop in order
Furnace P. < Max (2/3)

Trip Solid Fuel
ID. Fan running
Trip Soot Blower
HP Blower start
Trip Oil
Drum level > min (2/3)
SA. Fan running Trip Sand
PA. Fan running Trip Bottom Ash
HP. Blower P. > min Trip Lime Stone

PA. Flow to grid > min
Flue gas T after Furnace < max

100
Purge
— To carry out combustible gases
— To assure all fuel are isolated
from furnace
— Before starting first burner for
cold start
— If bed temp < 600 C or OEM
recommend and no burner in
service
— Total air flow > 50%
— 300 sec for purging time
101
Purge
NFPA85: CFB Boiler purge logic
102
Start up burner
— Help to heat up bed temp to allowable temperature for
feeding solid fuel
— Will be stopped if bed temp > 850 C
— Before starting, all interlock have to passed
— Main interlock
— Oil pressure > minimum
— Control air pressure > minimum
— Atomizing air pressure > minimum
103
Start up burner
NFPA85 - Typical burner safety for CFB boiler
104
Drum and DA low level cut-off
— Test for safety
— During burner are operating
— Open drain until low level
— Signal feeding are not allow
— Steam drum low level = chance
to overheating of water tube
— DA low level = danger for BFWP
105
Boiler warm up
— Gradually heating the boiler to reduce the effect of
thermal stress on pressure part, refractory and drum swell
— Increase bed temp 60-80 C/hr by adjusting SUB
— Control flue gas temperature <470 C until steam flow >
10% MCR
— Close vent valves at drum and SH when pressure > 2 bar
— Continue to increase firing rate according to
recommended start up curve
— Operate desuperheater when steam temperature are with
in 30 C of design point
— Slowly close start up and drain valve while maintain steam
flow > 10% MCR
106
Feed bed material
— Bed material should be sand which size is according to
recommended size
— Start feed sand when bed temp >150 C
— Do not exceed firing rate >30% if bed pressure <20 mbar
otherwise overheating may occur for refractory and nozzle
— Continue feed bed material unit it reach 30 mbar
107
Feed solid fuel
— Must have enough bed material
— Bed temperature > 600 C or manufacturer
recommendation or refer to NFPA85 Appendix H
— Pulse feed every 90 s
— Placing lime stone feeding, ash removal system
simultaneously
— Slowly decrease SUB firing rate while increasing solid fuel
feed rate
— Stop SUB one by one, observe bed temperature increasing
— Turn to auto mode control
108
Rise to MCR
— Continue rise pressure and temperature according to
recommended curve until reach design point
— Drain bottom ash when bed pressure >45-55 mbar
— Slowly close start up valve
— Monitor concerning parameters
109
Changing Boiler load (manual)
— Increasing — Decreasing
- manual increase air flow - manual decrease air flow
- manual increase fuel flow - manual decrease fuel flow
- monitor excess oxygen - monitor excess oxygen
- monitor steam pressure - monitor steam pressure
110
Furnace and Emission Monitoring
— Furnace and emssion

- monitor fluidization in hot
loop
- monitor gas side pressure drop
- monitor bed pressure
- monitor bed temperature
-monitor wind box pressure
- monitor SOx, Nox, CO
111
Bottom ash and Soot Blower
— Bottom ash drain — Soot blower

- automatic or manual draining - initiate soot blower to clean
of bottom ash shall be judged by the heat exchanger surface in
commissioning engineer for the convective part
design fuel. - frequent of soot blowing
- when fuel is deviated from the depend on the degradation of
design, operator can be judge by heat transfer coefficient.
themselves that draining need - normally 10 C higher than
to perform or not. normal value of exhaust
- bed pressure is the main temperature
parameter to start draining
112
— Boiler Walk Down
- boiler expansion joint
- Boiler steam drum
- Boiler penthouse
- Safety valve
- Boiler lagging
- Spring hanger
- Valve and piping
- Damper position
- Loop seal
- Bottom screw
- Combustion chamber
- Fuel conveyor
113
— Sizing Quality
- crushed coal, bed material, lime stone and bottom ash
sizing shall be periodically checked by the operator
- sieve sizing shall be performed regularly to make sure
that their sizing is in range of recommendation
114
6.5 Normal Shut Down
1. Reduce boiler load to 50% MCR
2. Place O2 control in manual mode
3. Monitor bed temperature
4. Continue reducing load according to shut down curve
5. Maintain SH steam >20 C of saturation temperature
6. Start burner when bed temperature <750 C
7. Empty solid fuel and lime stone with bed material >650 C
8. Decrease SUB firing rate according to suggestion curve
9. Maintain drum level in manual mode
10. Stop solid fuel, line stone, sand feeding system
115
11. Maintain drum level near upper limit
12. Continue fluidizing the bed to cool down the system at 2
C/min by reducing SUB firing rate
13. Stop SUB at bed temperature 350 C
14. Continue fluidizing until bed temperature reach 300 C
15. Slowly close inlet damper of PAF and SAF so that IDF
can control furnace pressure in automatic mode
16. Stop all fan after damper completely closed
17. Stop HP blower 30 S after IDF stopped
18. Stop chemical feeding system when BFWP stop
19. Continue operate ash removal system until it empty
116
20. Open vent valve at drum and SH when drum pressure
reach 1.5-2 bar
21. Open manhole around furnace when bed temp < 300 C
117
6.6 Emergency Shut down
— Boiler can be held in hot stand by condition about 8 hrs
— Hot condition is bed temp >650 C otherwise follow cold
star up procedure
— Boiler load should be brought to minimum
— Stop fuel feeding
— Wait O2 increase 2 time of normal operation
— Stop air to combustion chamber to minimize heat loss
118
6.7 Hot restart
— Purge boiler if bed temperature < 600 C
— Start SUBs if bed temperature > 500 C
— Monitor bed temperature rise
— If bed temperature does not rise after pulse feeding solid
fuel. stop feeding and start purge
119
6.8 Malfunction and Emergency
— Bed pressure
— Bed temperature
— Circulation
— Tube leak
— Drum level
120
Bed Pressure
Bed pressure is an one of importance
parameter that effect on boiler efficiency
and reliability.
Measured above grid nozzle about 20 cm.
Pf= 0
Pb
Pw
FI
121
Bed Pressure
— Effect of low bed pressure
- poor heat transfer
- boiler responds
- high bed temperature
- damage of air nozzle and refractory
— Effect of high bed pressure
- increase heat transfer
- more efficient sulfur capture
- more power consumption of fan
122
Bed Pressure
— Cause of low bed pressure
- loss of bed material
- too fine of bed materials
- high bed temperature
— Cause of high bed pressure

- agglomeration
- too coarse of bed material
123
Bed Temperature
— Measured above grid nozzle about
20 cm
— Measured around the furnace cross
section
— It is the significant parameter to
operate CFB boiler
124
Bed temperature
— Effect of high bed temperature
- ineffective sulfur capture
- chance of ash melting
- chance of agglomeration
- chance to damage of air nozzle
125
Bed temperature
— Cause of high bed temperature
- low bed pressure
- too coarse bed material
- too coarse solid fuel
- improper drain bed material
- low volatile fuel
- improper air flow adjustment
126
Circulation
— Circulation is particular
phenomena of CFB boiler.
— Bed material and fuel are
collected at cyclone separator
— Return to the furnace via loop
seal
— HP blower supply HP air to
fluidize collected materials to
return to furnace
127
Circulation
— Effect of malfunction circulation
- No circulation result in forced shut down
- high rate of circulation
- high circulation rate need more power of blower
- low rate of circulation
128
Circulation
— Cause of malfunction circulation
- insufficiency air flow to loop seal nozzle
- insufficient air pressure to loop seal
- plugging of HP blower inlet filter
- blocking or plugging of loop seal nozzle
-
129
Tube leak
— Water tube leak
- furnace pressure rise
- bed temperature reduce
- stop fuel feeding
- open start up valve
- don’t left low level of drum
- continue feed water until flue gas temp < 400 C
- continue combustion until complete
- small leak follow normal shut down
130
Drum level
Sudden loss of drum level
- when the cause is known and immediately correctable
before level reach minimum allowable. Reestablish steam
drum level to its normal value and continue boiler
operation
-if the cause is not known. Start immediate shut down
according to emergency shut down procedure
131
Drum level
Gradual loss of drum level
- boiler load shall be reduced to low load
- find out and correct the problem as soon as possible
- if can not maintain level and correct the problem, boiler
must be taken out of service and normal shut down
procedure shall be applied.
132
7. Maintenance
133
Before maintenance work
— Make sure that all staff are understand about safety
instruction for doing CFB boiler maintenance work
— Make sure that all maintenance and safety equipments
shall be a first class
134
Overview Boiler Maintenance
Refractory and tube are the main
area that need to be checked
135
6.1 Windbox Inspection
— Inspect sand inside windbox
after shutdown
— Drain pipe
— Crack
— Air gun pipe
— Refractory
— Crack, wear and fall down inspect Drain pipe
by hammer(knocking) if burner is
under bed design
136
6.2 Furnace Inspection
— Nozzle :
— Wear
— Fall-off
— Refractory
— Crack, wear and fall down inspect
by hammer knocking if burner is
under bed design
— Feed fuel port Refractory
— Wear
— Crack
— Burner
Burner Feed Fuel

137
Nozzle
6.2 Furnace Inspection
— Limestone port
— Crack
— Deform
— Refractory damage at connection
between port and refractory
— Secondary & Recirculation Air
port
— Crack
— Deform
— Refractory damage at connection
between port and refractory
— Bed Temperature
— Check thermo well deformation
— Check wear
Secondary & Recirculation Air port
138
6.3 Kick-Out Inspection
— Refractory
— Wear
— Crack and fall down by
hammer(knocking)
— Water tube
— Wear
— Thickness
139
6.3 Kick-Out Inspection
— Water Tube:
— Thickness measuring
— Erosion at corner
— CO Corrosion due to incomplete
combustion at fuel feed side.
— Defect from weld build up
— Water tube sampling for internal
check every 3 years
Inside water tube inspect by borescope

welded build up excessive metal because use welding rod
size bigger than tube thickness 140
6.4 Superheat I (Wingwall)
— Water Tube:
— Erosion at tube connection
— Refractory
hammer(knocking)
— Guard
— Crack
— fall down
141
6.4 Superheat I (Omega Tube)
— Offset Water Tube:
— Erosion at offset tube
Omega Guard
— SH tube
— Omega Guard
— Crack
— fall down
Offset Water 142
Tube
6.5 Roof
— Water Tube:
— Erosion
— Refractory
— Crack, wear and fall down by
hammer(knocking)
143
6.6 Inlet Separator
— Water Tube:
— Thickness measuring near opening
have more erosion than another
tube because of high velocity of flue
gas
— Refractory
— Crack, wear and fall down by
hammer(knocking)
144
6.7 Steam Drum
— Surface :
— Surface were black by magnetite
— Deposits
— Deposits at bottom drum need to
check chemical analysis
— Cyclone Separator
— Loose
— Demister
— Blowdown hole
— Plugging
— U-Clamp
— Loose
Deposits at bottom drum

145
6.8 Separator
— Central Pipe:
— Deformation
— Crack
— Refractory
— Wear at impact zone due to high
impact velocity
hammer(knocking)
146
6.9 Outlet Separator
— Water Tube
— Tube Thickness
— Erosion
— Outlet Central Pipe:

—Support or Hook
— Refractory
—Crack and fall down by
hammer(knocking)
147
6.10 Screen Tube
— Water Tube
— Thickness measuring upper part of
screen tube at corner have more
erosion than another area because
of high velocity of flue gas
— Guard
— Loose
— Refractory
— Crack and fall down by upper part of screen tube at corner have more erosion
hammer(knocking)
Weld build up or install guard to prevent tube erosion 148

6.11 Superheat Tube
— Tube
— High erosion between SH tube and
wall
— Steam erosion due to improper soot
blower
— Guard
— Fall down
— Crack
149
6.12 Economizer
— Water Tube
— High erosion between economizer
tube and wall
blower
— Guard
— Fall down
— Crack
Guard
Install guard to
prevent tube erosion 150
6.13 Air Heater
— Tube
— Cold end corrosion due to high
concentrate SO3 in flue gas
blower
Inlet air heater
Cold end corrosion due to SO3 in fluegas 151

8. Basic Boiler Safety
152
Warning
Operating or maintenance procedure which, if

not as described could result in injured death
or damage of equipment
153
General safety precaution
— Electrical power shall be turned off before performing
installation or maintenance work. Lock out, tag out shall
be indicated
— All personal safety equipment shall be suit for each work
— Never direct air water stream into accumulation bed
material or fly ash. This will become breathing hazard
— Always provide safe access to all equipment ( plant from,
ladders, stair way, hand rail
— Post appropriate caution, warning or danger sign and
barrier for alerting non-working person
— Only qualify and authorized person should service
equipment or maintenance work
154
General safety precaution
— Do not by-pass any boiler interlocks
— Use an filtering dust mask when entering dust zone
— Do not disconnect hoist unless you have made sure that
the source is isolated
155
Equipment entry
— Never entry confine space until is has been cooled, purged
and properly vented
— When entering confine space such as separator, loop seal
furnace be prepared for falling material
— Always lock the damper, gate or door before passing
through them
— Never step on accumulation of bottom ash or fly ash. Its
underneath still hot
— Never use toxic fluid in confine space
— Use only appropriate lifting equipment when lift or move
equipment
156
Equipment entry
— Stand by personnel shall be positioned outside a confine
space to help inside person incase of emergency
— Be carefully aware the chance of falling down when enter
cyclone inlet or outlet.
— Don not wear contact lens with out protective eye near
boiler, fuel handing, ash handing system. Airborne particle
can cause eye damage
— Don not enter loop seal with out installing of cover over
loop seal downcomer to prevent falling material from
cyclone
157
Operating precautions
CFB boiler process
— Use planks on top of bed materials after boiler is cooled
down. This will prevent the chance of nozzle plugging
— Do not open any water valve when boiler is in service
— Do not operate boiler with out O2 analyzer
— Do not use downcomer blown donw when pressure > 7
bar otherwise loss of circulation may occure
— Do not operate CFB boiler without bed material
— When PA is started. PA flow to grid must be increase to
above minimum limit to fully fluidized bed maerial
— Do not operate CFB boiler with bed pressure > 80mbar.
This might be grid nozzle plugging
158
— on cold start up the rate of chance in saturated steam shall
not exceed 2 C/min
— On cold start up the change of flue gas temp at cyclone
inlet shall not exceed 70 C/min
— Do not add feed water to empty steam drum with
different temperature between drum metal and feed water
greater than 50 C
— All fan must be operated when add bed material
159
Refractory
— When entering cyclone be aware a chance of falling down
— Refractory retain heat for long period. Be prepared for hot
surface when enter this area
— An excessive thermal cycle will reduce the life cycle of
refractory
— After refractory repair, air cure need to apply about 24 hr
or depend on manufacturer before heating cure
— Heating cure shall be done carefully otherwise refractory
life will be reduced
160
Solid Fuel
— Chemical analysis of all solid fuel shall be determined for
first time and compared with OEM standard
— Sizing is important
— Burp feeding shall be performed during starting feeding
solid fuel instead of continuous feeding
161
9. Basic CFB Boiler Control
162
— Basic control
— Furnace control
— Main pressure control
— Main steam pressure control
— Drum level control
— Feed tank control
— Solid fuel control
— Primary air control
— Secondary air control
— Oxygen control
163
Basic control
— Simple feedback control
PR IM ARY VA RIA B LE
XT
K PR O CE S S
SE T P OIN T
A T A
f(x)
M A NIP U LAT E D VAR IA BLE
164
Basic control
— Simple feed forward plus feedback control
P R IM A R Y VA R IA B L E
XT
SECO NDARY
VA R IA B L E
YT
P ROCE SS
S E T P O IN T
A T A
f(x)
M A N IP U L AT E D VA R IA B LE
165
Basic control
— Simple cascade control
PR IM ARY VA RIABLE
XT
SEC O N DA RY
VAR IA BLE
ZT
PR O C ESS
SE T PO IN T
A T A
f(x)
M AN IPU LATED VAR IABLE
166
Basic control
Control Mode of PID
-MAN (Manual)
-AUT (Automatic)
-CAS (Cascade)
PID
SP
Percent 0-100 % PV CO 0-100%
Eng. Unit 0-15 m3/h 0-100% (closed à open)

Electrical signal 4-20 mA 4-20 mA
0-15 m3/h Signal to open

167
Feed water control
PID PID
Make up water
PT
Heating steam
LT
Pressure Level
-Manual mode 0-100% heating steam valve -Manual mode 0-100% make up water valve
position
-Auto mode, specify level set point
-Auto mode, specify pressure set point
-Temperature compensation
-Temperature compensation
-Protection, high level over flow
168
Drum Level control
Main steam Pressure
Main steam flow
A, SP
Manual mode, 0-100%
control valve
Auto mode, specify drum
level. Automatically adjust
valve Control valve
M, 0-100%
Protection
-lower limit
DP feed -2/3 principle
water pump - 10 s delay
-Close steam valve for low level
169
Main steam pressure control
PV
SP
FF
CO
170
Main steam
Pressure
Combustion
Total air SP Total Fuel SP
Calculation
X -
PA SP SA SP Fuel1 SP Fuel2 SP Fuel3 SP
PA.Fan SA.Fan Conveyor1 Conveyor2 Conveyor3
171
Solid Fuel Control
Cascade PID
Auto
WT
Manual M
Manual : speed of coal conveyor is

specified by operator
Auto : operator specify fuel flow load
Cascade: fuel flow set point calculated by
main steam pressure control
172
Primary air control
Manual: position of damper is
specified
Auto PID Auto: desired air flow is specified by
Cascade
operator
Cascade: set point is calculated from
master combustion
Flow (interlock) > minimum
PA wind box P > minimum
Manual
M
PV PA running
FT
173
Secondary air control
Auto PID FT
Cascade
Upper SA
PID Auto
Cascade
Manual
Manual
M
PV Manual
FT PT FT
Lower SA
174
HP Blower Control
— Pressure is controlled by control valve
— Control valve is connected to primary air
— It will release the air to primary air duct if pressure higher
than set point
— If operating unit stop due to disturbance or pressure fall
down, stand by unit shall be automatically started
— Pressure should be higher than 300 mbar, boiler interlock
— Pressure < 350 mbar parallel operation start
175
Furnace Pressure control
Auto PID Auto PID
Furnace PT
pressure
2/3 furnace P < max (35 mbar)
M Manual
Manual
176
Lime stone control
— Lime stone can be control by
— lime stone/ fuel flow ratio
— SO2 feed back control
— Manual feed rate
177
Fuel oil control
Pressure control
Auto
Pressure
control valve
M
Manual
Flow control
valve 178
Referenced
• Prabir Basu , Combustion and gasification in fluidized bed, 2006
• Fluidized bed combustion, Simeon N. Oka, 2004
• Nan Zh., et al, 3D CFD simulation of hydrodynamics of a 150 MWe circulating fluidized bed
boiler, Chemical Engineering Journal, 162, 2010, 821-828
• Zhang M., et al, Heat Flux profile of the furnace wall of 300 MWe CFB Boiler, powder
technology, 203, 2010, 548-554
• Foster Wheeler, TKIC refresh training, 2008
• M. Koksal and F. Humdullahper , Gas Mixing in circulating fluidized beds with secondary
air injection, Chemical engineering research and design, 82 (8A), 2004, 979-992
179

CFB Boiler Design, Operation and Maintenance

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CFB Boiler Design, Operation and Maintenance

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CFB Boiler Design, Operation and

Know Principle Solve Everything

Distribution Size (micron)

75% <250 <550 <1190

50% <180 <450 <840

25% <130 <250 <590

100% >100 >420

Terminal velocity is the particle velocity when the

Furnace Upper SA:

Return leg and lift leg :

No SA, the suspension With SA 20% of PA,

higher solid recirculation rate

Pressure drop across the L-valve is

higher solid recirculation rate

Char burn under regime I

Char burn under regime I, II,

High combustion temperature result in high

-The effect of this particle size is not clear

- low fluidizing velocity cause defluidization, hot spot and sintering

Sintering tendency of fuel is indicated by the following

In a CFB boiler, fine solid particles

Heat transfer coefficient is proportional to the square root of suspension density

Low suspension density low

Moisture in fuel Unburned in fly ash

Moisture in fuel fly ash

— The drag force on the particle can be written as

— Under steady state drag force = centrifugal force

— Vr can be considered as index of cyclone efficiency, from

- Higher entry velocity

— Actual operation, the cut-off size diameter will be defined

Boiler Interlock Purge

Low level cut off

30-50 mbar, Tb 550-600 C

2.Start HP Blower 4.Start PA.Fan

Furnace P. < Max (2/3)

SA. Fan running Trip Sand

PA. Fan running Trip Bottom Ash

HP. Blower P. > min Trip Lime Stone

Flue gas T after Furnace < max

— Furnace and emssion

— Bottom ash drain — Soot blower

— Cause of high bed pressure

Burner Feed Fuel

Secondary & Recirculation Air port

Inside water tube inspect by borescope

Offset Water 142

Deposits at bottom drum

— Outlet Central Pipe:

Weld build up or install guard to prevent tube erosion 148

Inlet air heater

Cold end corrosion due to SO3 in fluegas 151

Operating or maintenance procedure which, if

M A NIP U LAT E D VAR IA BLE

M AN IPU LATED VAR IABLE

Percent 0-100 % PV CO 0-100%

Eng. Unit 0-15 m3/h 0-100% (closed à open)

0-15 m3/h Signal to open

PA SP SA SP Fuel1 SP Fuel2 SP Fuel3 SP

PA.Fan SA.Fan Conveyor1 Conveyor2 Conveyor3

Manual : speed of coal conveyor is

Auto PID Auto PID

2/3 furnace P < max (35 mbar)

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