Nigerian Journal of Tropical Engineering

Vol. 7, No. 2, 2011, PP. 61-72, ISSN 1595-5397.

DESIGN, CONSTRUCTION AND PERFORMANCE EVALUATION OF

A FLUIDIZED BED COMBUSTOR
I.I.Ozigis*, H. Dandakouta** and G. Egbo**

idris.ozigi@yahoo.com; dandakuta@yahoo.co.uk; gegbo2000@yahoo.co.uk.

*Department of Mechanical Engineering, University of Abuja

**Mechanical/Production Engineering Programme,

Abubakar Tafawa Balewa University, Bauchi.

ABSTRACT
The design, construction and performance evaluation of a square duct fluidized bed
combustor running on lignite-poultry droppings mixtures as fuel was carried out. Empirical
correlations were used to design and construct the combustor using mild steel plate and
refractory bricks. Combustion parameters and experimental results were used on Matlab
program to generate thermal power, heat transfer between bed and combustor wall and
between tube surface and steam as well as efficiency of the fluidized bed combustor. The
thermal power of the fluidized bed combustor ranges from 40 kW to 80 kW when burning
fuel mixture of lignite-poultry droppings ratios of 100:0;90:10;70:30;50:50 and 0:100) at
average fuel feed rate of 0.015 kg/s and steam flow rate of 0.016 kg/s. Steam temperature of
443 K with potential of generating thermal power of 65 kW was obtained at fluidized bed
combustor efficiency of 39 % burning fuel mixture of lignite-poultry droppings (ratio 70:30).
The maximum heat transfer rate between tube surface and steam was 25 kW at 545 K tube
surface temperature burning fuel mix ratio of 90:10 (lignite: poultry droppings). Similarly,
the maximum heat transfer flux between bed and combustor wall was 13 kW/m2 when bed
temperature was regulated to 1145 K while burning single fuel (lignite).

1. INTRODUCTION combustion, heat transfer and avoidable

A fluidized bed combustor was designed,
constructed, tested and found suitable for
providing fluidization and burning fuel
mixtures of Maiganga lignite and poultry
droppings. The performance analysis of a
fluidized bed combustor entails an energy
balance and efficiency determination.
When fuels are supplied and burnt in
combustor, heat is released, which may be
transferred to feed water in heat-exchanger
tube; for the purpose of generating steam.
The heat transfer is related to some
governing parameters such as overall heat
transfer coefficient, surface area, fluid
temperature, mass flow rate, specific heat
capacity and change in temperature across
heat transfer surfaces. Therefore, fluidized
bed combustor efficiency can be related to
losses [1].
A direct method of efficiency
calculations was used due to its quick, few
parameters for computation and for a small
batch steam generator. Direct method
needs only useful output (steam) and the
heat input (fuel) for evaluating fluidized
bed combustor efficiency. The other
parameters were lower calorific value of
fuel used, temperature and enthalpy of
saturated steam as well as temperature and
enthalpy of feed water. The indirect
method of efficiency entails measuring all
the losses occurring in the combustors.
The loss of heat in a fluidized bed
combustor principally occur, due to dry
flue gas, radiation, evaporation of moisture
in air, fuel and H2 in fuel as well as
unburnt fuel in fly ash and bottom ash. The

61
 Design, Construction and Performance Evaluation of a Fluidized Bed Combustor
requirements for calculating indirect
method are ultimate analysis of fuel, lower
calorific value, percentage of O2 or CO2 in
flue gas, temperature and humidity of air.
The efficiency can be arrived at, by
subtracting the heat loss fractions from
100 % [1].
The growth of fluidized bed
combustor was traced in US, from 1965
with start of 500 kW fluidized bed test
plant in Alexandria, Virgina, that lead to
30 MW prototype at Monongahda Power
plant in the mid 1970s [2]. A commercial-
sized fluidized bed combustor was
established in Georgetown University in
1979 which still operates today and 300
MW at North side Station was
commissioned on Oct 14, 2002, enough to
light over 250,000 average households [2].
A detailed design procedure for fluidized
bed combustor was outlined for solid,
liquid and gaseous fuels [3]. A fluidized
bed combustor was designed and
Table 1: Some Properties of Air Fluidized Bed Combustor
S/N Description Value
1 Volumetric Air Flow Rate, Fav 0.121 m3/s
2 Air Fuel Ratio AF
3 o ρ1
Air Density at 30 C,
4 ρ2
Air Density at 850oC
5 ρ3
Average Air Density
6 Fluidization Velocity, U
7 Turbulence Time, t
The below expression was used to
calculate mass flow rate [6] ma:
. .
m a = Fam (1 + 1 ) ≅ ρ 3 Fav (1 + 1 ) .. 1
AF AF
The values mentioned above were
substituted into equation [1] to give:
.
m a = (0.76 × 0.121)(1 + 1 ) = 0.096 kg s
23
i. Volume of Combustion Chamber
62
constructed for firing oil shale at Jordan
[4] . The volume of fluidized bed
combustor for firing solid fuels was used
in performance analysis [5]. The volume
of the combustion chamber must be
sufficient to provide the needed residence
time for the flow rate of air and fuel to
undergo complete combustion [6].
2. DESIGN OF FLUIDIZED BED
COMBUSTOR
The combustor consists of plenum,
combustion chamber, free board and
refractory lined wall to minimize heat loss
to surrounding. Combustion chamber can
either be square or circular, however, the
area of bed and depth are also function of
air power to meet required pressure to
fluidize bed materials [1]. Using empirical
correlations, dimensions of the square-duct
fluidized bed combustor was designed [6].
The values shown in Table 1 are from a
work [7].
23
1.2 kg/m3
0.3145 kg/m3
0.76 kg/m3
0.681 m/s
0.5 sec
The volume of combustion
chamber (V) was obtained by substitution of
ma, t and ρ 3 in equation 2 [5, 6]:
.
V = ma × t …2
ρ3
V = 0.096 × 0.5 = 0.0632 m 3
0.76
ii. Combustor Area
The combustor area, A, was also
obtained as (6):
 I.I.Ozigis, H. Dandakouta and G. Egbo

. d bm − d b − 0.3 Z
A= ma …3 =e dt
… 7
ρ ×U o
d bm − d bo

A= 0.096 = 0.186 m 2 where;

0.76 × 0.681
iii. Height of Combustor Chamber
(Hd)
The height of the combustion
chamber is then obtain as follows (6):
V
Hd =
A …4
0.063
Hd = = 0.338 m
0.186
iv. Combustor Width(L1)
The combustor width may be found
from the square root of area (A):
A = L12
…5
L1 = 0.186 = 0.43 m
i. Internal Width of the
Combustor
The combustor was gas-tight with
minimum heat loss from interior to outside
with refractory brick of 0.05m thick. Then
internal width of the combustor:
d t = L1 − 2t ref … 6
where;
tref is refractory thickness =0.05 m thick
d t = 0.43 − 2(0.05) = 0.33 m
v. Free board and Overall Height of
Fluidized Bed Combustor
The overall height of fluidized bed
combustor (Ht) [8], is the height for
combustion chamber (Hb) and free board
(Hf) without erection column and flue gas
cleaning facilities. The calculations were
based on internal width of the combustor
and fluidization velocity of the bed
materials. The effective bubble diameter
(db) just above distributor as given (9):
Z is distance above the air distributor =33
cm (9)
d b = 48 − 39e −0.3( 33) / 33 = 9 cm
Transport Disengaging Height (TDH)
[10]:
TDH = 12d b …8
TDH = 12 × 9 = 108 cm
Combustion chamber is the lower dense
bed that includes fuel entry and intense
combustion processes [6, 8 and 9].
The freeboard height, Hf, is taken to be 20
% greater than TDH [10]:
H f = 1.2TDH … 9
H f = 1.2 × 108 = 130 cm
Height of combustor, (Ht:) may be
determined as follows:
Ht = H f + Hd … 10
H t = 130 + 33 = 163 cm
Since height to internal width ratio is
greater than 4, i.e:
1.63/0.33 =5.0.; Then the bed will operate
in slugging regime
3. CONSTRUCTION
The fluidized bed combustor is a square
duct of cross sectional area 460 mm by
460
mm and 1630 mm formed using 6 mm
thick mild steel plate as shown in Plate 1.
The plate and angle iron were cut using
angle cutting machine. The joining
methods were bolts and nuts as well as arc
welding using gauges 10 and 12-
electrodes. There were 5 mm thick angle-
iron reinforcement on all edges and 50 mm
flanged round top and bottom of the
chamber with two drilled holes at each
side. These were to provide airtight sealing
for the freeboard when mated with

63
 Design, Construction and Performance Evaluation of a Fluidized Bed Combustor

combustion chamber and steam separator terminates at outside of the combustor

at bottom and top, respectively. The lining with flange for mating with screw feeder.
was made up of 60mm thick refractory There were inlet and outlet nipples for
firebrick from bottom to top in interlock connection to evaporator heat exchanger
pattern. 3 mm fire clay mortar was placed tube. Air enters through the air distributor
in between sides of firebricks during lining made of sandwich screens of 0.72mm
Service openings were drilled through for diameter and reinforced with 6mm thick
thermocouple, tubes and feed pipe. 85 mm plate at the edges as the flange. The
internal diameter pipe serves as water- specifications of component parts of the
cooled feed pipe, which extends to middle fluidized bed combustor are as shown in
of the combustor on one hand and Table 2 and Plate I.
Table 2: Specifications of the Fluidized Bed Combustor
No Component Parts Thickness Dimension, mm
1. Duct Square Combustor Column 6 mm, 3.0 x 0.56 x 0.56 mild steel
2. Centrifugal Fan 3 mm, 0.8 x 0.75 x 0.17 mild steel, 5kW,
3. Electric Motor for Fan 5.5 kw, 3ψ, 2880 rpm, 50Hz,
Gear Motor for Screw Feeder, 0.4 kW, 3ψ, 1500 rpm, 50Hz
Electric Water Pump 0.4 kW, 1ψ, 1500 rpm, 50Hz
4. Heating Element 1.4 mm 4 kw, 1ψ, 220v, 0.85∩ x 15 m
5. Plenum and Column 6 mm, 0.45 x 0.45 x 0.20 mild steel
6. Air Distributor 3 mm 40,000 holes each 0.72 mm diameter,
0.45 m x 0.45 m, steel, screens
7. Heat Exchanger 1 mm ∅.2 x 40 m long copper tube
8. Wet and Steam Tanks, 2 3 mm, 0.4 m x 0.2 m x 0.2 m mild steel
9. Cyclone (mild steel) 3 mm, ∅o0.15 m x 0.30 m with long cone
10. Feed Hopper (mild steel) 3 mm, ∅o0.15 m x 0.30 m with short cone
11. Enugu Fired Fireclay Brick 80 0.22 x 0.12 x 0.06 m
12. Bearings 2 pieces ∅I 0.025 x ∅o 0.052 x 0.018 m
13 Screw Feeder 1 ∅I 0.1 m x 0.3 m screw length
14 Combustion Chamber 6 mm 0.46 m x 0.46 m x 1.0 m with feed pipe
15 FreeBoard 6 mm 0.46 m x 0.46 m x 0.63 m with hand hole
16 Economizer 3 mm Oo0.25 m x 0.35 m long cools cyclone
17 Start-Up Burner Grate 6 mm 0.4 m x o.4 m with 10 mm holes

64
 I.I.Ozigis, H. Dandakouta and G. Egbo

Plate 1: isometric view of the fluidized bed combustor.

4. PERFORMANCE ANALYSIS Assuming there is no heat loss to

OF THE FLUIDIZED BED surrounding and also potential and kinetic
COMBUSTOR energies are negligible, then the bed
i. Energy Balance between Bed and temperature (Tb) may be determined from
Combustor Wall energy equation as:

65
 Design, Construction and Performance Evaluation of a Fluidized Bed Combustor

dTb (Tb − Tw ) Cs is specific heat capacity of steam (J/kg

= … 11
dt ΔX 1 ΔX 2 K)
mf Cf ( + ) hs is convective heat transfer coefficient(
k1 Aw k1 Aw
W/m2K) for hot turbulent fluid.
At is area of tube for water-steam flow(m2)
where mf is mass of tube material (kg)
Cf is specific heat capacity of copper tube iv. Energy Balance between Outer
(J/kg K) Combustor Wall and
K1 is carbon steel thermal conductivity= 45 Surrounding Air
W/mK [10]. The combustor wall temperature is then
determine as:
K2 is Refractory brick(fireclay) thermal dTw hw Aw (Tw − Ta )
= .... 14
conductivity = 1.1 W/mK [10]. dt mw C w
Δ X 1 is thickness of mild steel plate
determined to be 0.006 m where mw is mass of refractory material
Δ X 2 is thickness of refractory brick (kg)
determined to be 0.06 m Cw is specific heat capacity of refractory
Aw is area of heat flow perpendicular to material (J/kg K)
the combustor wall lining (m2) hw is heat transfer correllation for wall
Tbed is bed temperature (K) free convection is given [12]:
Tw is combustor wall temperature (K)
⎛ T − Ta ⎞
0.25

hw = 1.42⎜ w ⎟
ii. The Energy Balance between ⎝ L ⎠ … 15
Heat Exchanger Tube and Steam For laminar flow of .
The tube surface temperature is therefore L3 ρ 2 βgΔT
determined as follows (see fig.1): Gr = … 16
μ 2
dTt U t At (Tt − Ts )
= … 12
dt mt Ct
where mt is mass of tube material (kg) where β = 1/Tw, is the coefficient of
Ct is specific heat capacity of copper tube thermal expansion of the fluid in free
(J/kg K) convection (Fig.2), which is a reciprocal of
Ts is steam temperature (K) temperature, Tw .
Tt is tube surface temperature (K) ΔT is change in temperature = Tw-Ta
At is area of tube surface (m2) L is charasteristic length of the combustor
U is overall heat transfer coefficient is worked out from the relation as:
between tube surface and steam (W/m2K) 1 1 1
= + … 17
iii. Energy Balance for the Steam L L h Lv
Generation(between Feed Water where Lv and Lh refer to the significant
and Steam) vertical and horizontal dimensions of the
The steam tempereature is therefore combustor.
calculated as below (see Fig.1):
dTs hs At (Ts − Ta ) v. Efficiency of the Fluidized Bed
= Combustor
dt ms C s … 13 The fluidized bed combustor efficiency
where Ta is ambient water temperature can be evaluated by determination of
(K) useful steam output and heat input stated
ms is mass of steam (kg) [11]:

66
 I.I.Ozigis, H. Dandakouta and G. Egbo

M s (h − h f ) Numerical solutions for differential

η= 100% … 18 equations (11, 12, 13, 14 and 18) were
F f LCV
presented in form of Runge-Kutta
where Ff is fuel flow rate, kg/s, simultaneous equations for Matlab
LCV is lower calorific value of the fuel, program. The thermal power and
J/kg. efficiency of the combustor were
h is the heat required to evaporate one kg determined using sub models and were
of water from 25 oC to wet steam treated as single iteration within ranges of
temperature values provided. For each step, an iterative
hf is enthalpy of feed water, J/kg procedure was adopted for equating the
Ms is steam generation rate, kg/s energy balance equations of thermal
power, heat transfer between tube surface
vi. and steam, heat transfer between bed and
Computation Procedure
The input data for performance analysis wall and efficiency of the combustor;
models of fluidized bed combustor were which dependent on time were entered into
the experimental values obtained for fuel matlab program. Then, the Matlab
(Ff), air (Fa) and steam (Ms) flow rates as program was run. The end points are 0-
well as for the bed (Tbed), tube surface (Tt), 30mins with twenty (20) steps.
wall (Tw) and steam (Ts) temperatures.

o
CldS a
tem

Hot Flue Gas

L
Tt

hb K UA
te
S m
a

Hot Steam
Hot Flue Gas Q

ro
r1

Tt
Ts
hs , Ts

Electrical Analogy

. Tt ro ln roTs
k r1

Fig.1: heat transfer through the cylindrical tube.

67
 Design, Construction and Performance Evaluation of a Fluidized Bed Combustor
hg
Q
X0
X1 X1
X2
X2
Fig. 2: heat transfer through the square duct combustor wall
5. RESULTS AND DISCUSSIONS
The resulting improvements in the design
of the combustor leads to improved fuel
mixing with air that allows the fuel to burn
at lower temperature(1123 K) compared to
other coal-fired combustors (above 1300
K). This low temperature and refractory
bricks on the wall reduces heat loss as
radiation was drastically reduced. The use
of excess air at 100% increases bed
temperature but the heat losses through
flue gas pipe was recaptured and made to
pass through steam separator and
economizer tanks thereby providing
additional energy for the steam. The
mounting of steam separator on top of
freeboard is another innovation that
reduces heat loss which leads to increased
efficiency of the combustor. The average
combustor efficiency at increased load of
61 kW was 39 % compared to about 34 %
for coal-fired plant [13].
i. The Effect of Thermal Power on
Efficiency of the Fluidized Bed
Combustor.
68
ha
K1 K2 H
Q
Tb
A
Tw
L
Electrical Analogy
Tb x1 x2
Tw
K1A k2A
Fig 3: shows thermal power of the
fluidized bed combustor while burning
some fuel ratios (lignite-poultry
droppings). At the same temperature,
efficiency of the combustor running on
single fuel (poultry droppings) was higher
than when it runs on lignite alone. The
increased reaction rate increases the
thermal power, which also increases the
combustor efficiency. For fuel mix ratio of
90:10 (lignite: poultry droppings), when
the thermal power was 45 kW, the
combustor efficiency was 19 % but at 72
kW the efficiency was 33 %. Similarly, for
fuel mix ratio of 70:30, at thermal power
of 38 kW, combustor efficiency was 23 %
while at 61 kW, the efficiency was 39 %.
For fuel mix ratio of 50:50, at 33 kW, the
combustor efficiency was 26 % while at 53
kW, efficiency was 43 %. These are in
close agreement to data obtained from
thermal power plants whose capacities
ranges from 10 to 50 MW operating at
efficiencies ranging from 17.1 to 27.5 %
[14].
 I.I.Ozigis, H. Dandakouta and G. Egbo

60

Efficicency of Fluidized Bed Combustor
50

100%:0%(Lignite:Poultry Droppings)
40
90%:10%(Lignite:Poultry Droppings)

30
70%:30%(Lignite:Poultry Droppings)

20
50%:50%(Lignite: Poultry Droppings)

10 0%:100%(Lignite:Poultry Droppings)

0
0 20 40 60 80
Thermal Power, kW

Fig.3: thermal power against efficiency.

ii. Effects of Steam Temperature on temperature of 441 K, the values of

Thermal Power of the thermal power recorded were 79 kW, 76
Combustor kW, 68 kW, 60 kW and 42 kW for fuel
Fig.4 shows steam temperatures attained mix ratios stated above, respectively as
by various fuel mix ratios fired. The steam shown in fig.38. There is no significant
temperature and thermal power contributes loss in thermal performance in the
to the efficiency of the fluidized bed combustor for substitution of poultry
combusttor. The temperature of the steam droppings for lignite which is worthwhile
generated during the experiments were and saves lignite. This is in close
found to be within the range of 436 K-445 agreement with results found by co-firing
K for all the fuel mix ratios of 100:0, of several biomasses with coal in
90:10, 70:30, 50:50 and 0:100 (Lignite: combustors [15].
Poultry droppings) considered. At steam

90
80 100%:0%(Lignite: Poultry Droppings)
70
90%:10%(Lignite: Poultry Droppings)
Thermal Power, kW

60
50 70%:30%(Lignite: Poultry Droppings)

40
50%:50%(Lignite: Poultry Droppings)
30
20 0%:100%(Lignite: Poultry Droppings)

10
0
0 100 200 300 400 500
Steam Temperature,K

Fig.4: thermal power against steam temperatures

iii. The Effect of Heat Transfer on and rupture becomes frequent in fluidized
Tube Surface Temperature. bed combustor. Tube surface temperature
The transfer of heat to water through tube depends on several factors such as tube
result in losses via tube wall, surface material, coating and operating conditions
deposits and flow regimes which may lead of the combustor. The heat transfer rate
to reduced efficiency of the combustor ranges from 19 kW to 24 kW for all the
(Fig.5). During the experiments, the fuel mix ratios studied. At a heat transfer
measured tube surface temperatures were flux of 21 kW, the values of the tube
generally below 677 K, the critical surface recorded temperature were 539 K,
temperature above which tube get burnt 534 K,525 K, 517 K and 498 K when test

69
 Design, Construction and Performance Evaluation of a Fluidized Bed Combustor

was carried out with fuel mix ratios of surface temperature that ranges from 573
100:0, 90:10, 70:30, 50:50 and 0:100 to 800 K as obtained by some researchers
respectively as shown in fig.39. These [16].
results are in close agreement with tube

600

100%:0%(Lignite: Poultry Droppings)
500

90%:10%(Lignite: Poultry Droppings)

70%:30%(Lignite: Poultry Droppings)
400
Tube Surface Temperature, K

50%:50%(Lignite: Poultry Droppings)

0%:100%(Lignite: Poultry Droppings)
300

200

100

0
0 5 10 15 20 25

Heat Tramsfer Rate between Tube Surface and Steam, kW

Fig.5: tube surface temperature against heat transfer rate.

iv. The Effects of Heat Transfer on better insulating materials and elimination
Combustor Wall. of cracks and hot spots. At heat transfer
The heat transfer rate between bed and flux of 11.4 kW/m2, the bed temperature
combustor wall was measured at a number were 1271 K, 1207 K, 1086 K, 972 K and
of locations on the combustor wall during 722 K for 100:0, 90:10, 70: 30, 50; 50 and
the experimental work as shown in Fig.6. 0:100 (Lignite: Poultry droppings)
The temperatures of the bed and outer respectively. Bed temperatures also vary
surface of wall were measured using K- along the height of the combustor and
type thermocouples. The heat transfer flux were controlled to be within the range of
varied between 11.4 and 12 kW/m2 for the 1000 to 1223 K for all the fuel mixtures
various fuel mix ratios considered in the investigated. The difference to an average
present study. To improve the efficiency of of 34.47 kW/m2 obtained by some workers
the fluidized bed combustor, wall heat was due to use of laser flux measurement
losses will have to be reduced via use of tool that gives more accurate results [17].

70
 I.I.Ozigis, H. Dandakouta and G. Egbo

1400
1200

Bed Temperature, K
100%:0%(Lignite:Poultry Droppings)
1000
800 90%:10%(Lignite: Poultry Droppings)

600 70%:30%(Lignite: Poultry Droppings)

400 50%:50%(Lignite: Poultry Droppings)
200
0%:100%(Lignite: Poultry Droppings)
0
0 20 40 60

Heat Transfer  Rate  between Bed and  Combustor wall.

Fig.6: bed temperature against heat transfer rate.

6. CONCLUSIONS REFERENCES
The design, construction and performance
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 Design, Construction and Performance Evaluation of a Fluidized Bed Combustor
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