CIRCULATING FLUIDISED BED COMBUSTION (CFBC) TECHNOLOGY FOR POWER

GENERATION -- Technology Status

1.0 THE FLUIDISED BED COMBUSTION PROCESS

For fuels with high moisture content and low heating value such as biomass, municipal wastes, paper
& pulp industry wastes, sludge etc. and small capacities, bubbling fluidised bed technology is
recommended. The circulating fluidised bed technology is considered suitable for waste fuels with a
high percentage of non-combustibles(heating value 5-35MJ/kg).

The Circulating Fluidised Bed Combustion technology is environmentally benign. The process
employs a Circulating fluidised bed combustor that operates at a temperature of around 800-900 0C.
The fuel(crushed coal) along with the sorbent(limestone) is fed to the lower furnace where it is kept
suspended and burnt in an upward flow of combustion air. The sorbent is fed to facilitate capture of
sulfur from the coal in the bed itself resulting in consequent low sulfur emission. The combustion air is
fed in two stages - Primary air direct through the combustor and Secondary air, way up the combustor
above the fuel feed point.

Due to high gas velocities the fuel ash and unburnt fuel are carried out of the combustor with the flue
gases. This is then collected by a recycling cyclone separator and returned to lower furnace.

The heat transfer surfaces are usually embedded in the fluidised bed and steam generated is passed
through the conventional steam cycle operating on Rankine Cycle. Alternatively, without the Fluid Bed
Heat Exchanger, the heat transfer surface may be distributed over the combustor and the convective
pass.
 Fluidized Bed Combustion Process Diagram (Lakeland, USA CFBC):

2.0 Advantages of Circulating Fluidised Bed Combustion Technology

 Fuel Flexibility

The relatively low furnace temperatures are below the ash fusion temperature for nearly all
fuels. As a result the furnace design is independent of ash characteristics which allows a given
furnace to handle a wide variety of fuels. Low-grade coals, high ash rejects, high sulfur coals,
lignite, biomass, wastes & other difficult fuels can be burnt easily in the CFBC boiler.

 Improved Combustion Efficiency

The long residence time in the furnace resulting from collection/recirculation of solid particulate
via the cyclone, plus the vigorous solids/gas contact in the furnace caused by the fluidisation
 airflow, result in high combustion efficiency, even with difficult-to-burn fuels. 98-99% carbon
burnout has been achieved. The very high internal & external recirculating rates of solids result
in uniform temperatures throughout the combustor.

 In-situ Pollution Control & Reduced Emissions

Desulfurisation is accomplished in the combustion zone itself by addition of limestone in the

bed. SO2 removal efficiency of 95% and higher has been demonstrated along with good
sorbent utilisation. Low furnace temperature plus staging of air feed to the furnace produce
very low NOx emissions. Chlorine & Fluorine are largely retained in ash.

 Operating Flexibility

Can be designed for cyclic or base load operation. Part loads down to 25% of MCR and load
change rates of up to 7% per minute are possible.

 Simplified Fuel Feeding

Fuel pulverisation not required and only crushing is sufficient for fuel feed.

 Proven Technology

Foster Wheeler has more than 150 CFB steam generators in operation. The commercial availability of
most of these units exceeds 98%.

3.0 CFBC System Components

The CFBC systems comprise of the following major components:

 Fluidised Bed Combustor & associated systems

 Fluid Bed Heat Exchanger
 Solids separation system - Recycling Cyclone, U-beam particle separators
 Conventional steam turbine systems
 Fuel Preparation & Feeding System
 Ash Removal System

3.1 Fuel Feed System

Fuel feed system is either pneumatic or wet type. Normally coal is fed as coal -water mixture as they
have demonstrated to burn more evenly. The optimum system design depends upon ash and sulfur
content in coal. For fuels with low ash contents, coal-water mixture has found favours since large
quantities of water are needed for coals with high ash, which affects its efficiency. The fuel is fed in
the form of coal-water paste with 25% water by weight. The fuel feed size is lower than 0.75 in.
3.2 Sorbent Feed System

Sorbents are not combustibles and are generally fed either continuously or intermittent. In the latter
case, lockhoppers are used. The sorbent is crushed to around 3 mm top size, dries and fed in lock
hoppers.

4.0 Technological Advancements

In addition to external particle recirculation CFB, internal recirculation CFB has been developed.
Internal recirculation CFB uses U-Beam separators installed in the flue gas exit path to collect and
recycle the solids directly to the bottom of the furnace. U-beams are a staggered array of stainless
steel channels in the furnace exit plane, which capture most of the solids suspended in the flue gas.
In addition, the multi cyclone dust collector captures finer solids, which pass through the U-beam, and
recycles them to the lower furnace in a controlled manner. The regulation of this secondary recycle
system offers furnace temperature control resulting in improved boiler performance. The manufacture
claim to achieve >99.8% particle collection efficiency for the two-stage particle separation system.
The IR-CFB operates at low flue gas velocities of 8 m/s as compared to 27 m/s with external
recirculation CFB. This reduces erosion problems in the furnace, which are a major cause for
maintenance problems in CFBC. This design uses significantly less amount of refractory due to
elimination of hot gas cyclone path. This IR-CFB technology is exclusively patented by Babcock &
Wilcox.

The CFBC process has been integrated with Advanced Pressurised Fluidised Bed Combustion
system. The fuel & sorbent are fed into a PFB either Circulating or Bubbling. Combustion is aided by
compressed air usually under a pressure of 10 to 14 bars at around 871 0C. A cyclone separates
particulate from pressurised flue gas stream and returns them to the bed. The flue gas undergoes a
final clean-up through ceramic candle filters before entering the combustion turbine at around 816 0C.
The waste heat from the combustion turbine is recovered in a HRSG that generates steam to drive
the steam turbine of the combined cycle.

Pressurised Circulating Fluidised Bed (PCFB) process has been preferred by Foster Wheeler over
the Bubbling bed. It offers higher combustion efficiency due to more carbon burnout in circulating
mode. Low sorbent consumption for the same sulfur removal because of increased efficiency. Better
NOx control from ease of staged combustion, since a circulating unit is taller and more slender. A
higher velocity in the circulating mode results in units of smaller size for the same capacity.

5.0 Technology Status

CFBC technology has been proven for all type of fuels including high ash coal, lignite, wood wastes,
refinery residue etc. There are over 310 operating CFBC boilers worldwide. Foster Wheeler has more
than 150 CFB steam generators in operation. The commercial availability of most of these units
exceeds 98%. M/s Lurgi Lentjes Babcock Energietechnik Gmbh (LLB), Germany has 42 CFBC steam
generators (>8700 MW) in operation worldwide. M/s Babcock & Wilcox have about 40 operating CFB
units worldwide.
LIST OF CFBC TECHNOLOGY SUPPLIERS WORLDWIDE

S. No. Name Of Technology Technical No. Of Operating Remarks

Supplier Collaboration Plants
1. Foster Wheeler, USA (47%) ------------- 150 Circulating fluid bed technology
2. Lentjes Energietechnik, Lurgi 42 (870 MW) Circulating fluid bed technology
Germany (7.7%)
3. Babcock & Wilcox, USA ------------- 40 Internal Circulation & Bubbling
fluid bed technology
4. ABB (14.5%)      
5. BHEL Lurgi 19  
6. GEC Alstom Stein Industrie, Lurgi 150  
(8.5%)
7. Austrian Energy & -------------   Bubbling, External/Internal
Environment Circulating FB
8. Kvaerner Pulping Oy, Finland     Cymic Advanced CFBC/
(8%) Bubbling Bed
9. Deutche Babcock (4.5%)      

The list of some major plants based on this technology worldwide is as below:

LIST OF MAJOR PROJECTS EMPLOYING CFBC TECHNOLOGY

S. No. NAME/COUNTRY SIZE FUEL COMM. REMARKS

DATE
MWe
1. Tri-state Generation & Trans. Co. 110 Coal 1987 Foster Wheeler
USA
2. Kainuun Voima Oy Finland 95 Coal, Peat, 1990 Foster Wheeler
Sludge
3. Vasikiluodon Voima Oy, Finland 125 Coal, Peat 1990 Foster Wheeler
4. ACE Cogeneration USA 110 Coal 1992 Foster Wheeler
5. Rheinisch-Westfalisches Elect. Works, 100 Brown Coal 1992 Foster Wheeler
Germany
6. Nelson Industrial Steam Company, 2 x125 Petroleum Coke 1992 Foster Wheeler (largest
USA petcoke CFB)
7. Nova Scotia Power Inc. Canada 180 Coal 1993 Foster Wheeler
8. IVO International Oy Finland 110 Peat 1995 Foster Wheeler
9. Colver Power Project USA 100 Bituminous 1995 Foster Wheeler
 Waste
10. Northampton Energy, USA 100 Anthracite 1995 Foster Wheeler
Waste
11. CMIEC/Neijiang, China 100 Anthracite Coal 1996 Foster Wheeler
12. Turow Power Station Poland 3x 235 Brown Coal 1998 Foster Wheeler Repowering
13. National Power Supply Thailand 2x 150 Coal, Bark 1998 Foster Wheeler
14. Asian Pulp & Paper Co. China 2x 100 Coal 1998 Foster Wheeler
15. EC Katovice S.A. Poland 180 Coal 1999 Foster Wheeler
16. Jacksonville 300   2003  

S. No. NAME/COUNTRY SIZE MWe FUEL COMM. DATE REMARKS

1. Emile Hutchet, Lorraine, France 125 Coal 1990 Alstom Stein Industrie
(Lurgi Tech.)
2. Provence/Gardanne power plant, 250 Coal 1995 Alstom Stein Industrie
France
SOx-380, NOx-280 & Dust-
20 mg/Nm3
3. Red Hills, Mississippi, USA, 2 X 250 lignite 2000 Alstom Stein Industrie
Choctaw Generation

S.No NAME/COUNTRY SIZE FUEL Comm REMARKS

MWe Date
1. Ultra Power, West Enfield, Maine, 77 Wood wastes 1986 Babcock & Wilcox
USA
2. Ebensburg Power Co. Pennsylvania, 172 Waste Coal 1990 Babcock & Wilcox
USA
3. Kanoria Chemicals Ltd. Renukoot, 81 High Ash Coal 1996 Babcock & Wilcox
India
4. Montana Dakota Utilities, USA 215 Lignite 1986 Babcock & Wilcox
Bubbling Fluidised
Bed
5. Bowater Inc, Tennessee, USA 144 Bark, Natural Gas, Paper Mill 1998 Babcock & Wilcox
Sludge
BFB retrofit
6. AES Beaver Valley, Pennsylvania, 121.5 Bituminous Coal 1999 Babcock & Wilcox
USA
7. Southern Indiana Gas Co Indiana, 299 High Sulfur Coal, Waste 2000 Babcock & Wilcox
USA Coal
8. Changguang Coal Mine Co. 155 High Sulfur Bituminous Coal 2000 Babcock & Wilcox
Zhejiang, China
9. Rostovenergo-Nesvetay Russia 163 High Ash Anthracite Coal 2000 Babcock & Wilcox

S. No. NAME/COUNTRY SIZE FUEL COMM. REMARKS

MWe DATE
1. Vapo Oy, Lieska, Finland 30 biomass 1994 8 MWe + 14 MW heat + 8 MW steam.
1st Cymic CFBC
2. Elektrocieplownia Tychy S.A. Poland 37 Coal 1999 Kvaerner Pulping’s Cymic CFBC
3. Clonbulloge, Offaly, Ireland, 120 peat 2001 Kvaerner Pulping’s Bubbling CFBC
Edendry Power

1. KEPCO, Seoul, Korea 2X 200 anthracite 1999 High ash, highly erosive coal;

6.0 COSTS

The investment costs of projects based on the CFBC technology are much lesser than the
conventional PC based plants. ($900-$950/kW)

7.0 Indian Scenario

Fluidised Bed Combustion is a proven & established technology (not new, in contrast to general
perception). Pilot and experimental FBC boilers were in operation as early as 1977 in India at BHEL,
Trichy ; CFRI, Dhanbad etc. All these plants are still in operation. However FBC plants are
economical only for poor quality fuels, which cannot be fired in conventional boilers. Initially these
boilers were used for co-generation and process gas/steam applications at industrial installations.
Later small size captive power plants also used FBC boilers. The common Indian fuels used include
high ash coals, coal washery rejects, biomass and lignite.

All initial FBC boilers, before 1992, were invariably supplied by BHEL and based on obsolete Lurgi
bubbling bed FBC technology licensed to BHEL by Lurgi Lentjes Babcock. Later Foster Wheeler,
USA supplied few Circulating FBC boilers in 1992-95 through its Indian licensee, ISGEC John
Thompson. Currently Foster Wheeler is directly executing two new orders from Rain Calcining, Vizag
(25MW, petroleum coke) and Mysore Paper Mills, Bhadravati(20MW, multi-fuel). Babcock & Wilcox
has also supplied few bubbling bed FBC boilers in India since 1992. The most important of these is
the Kanoria Chemicals, Renukoot 81MW captive power plant based on the most advanced Internal-
particle recirculation FBC. Interestingly, B&W currently does not have any new order on hand in India.
Another notable fact is that B&W does not have any experience with petroleum-coke fired FBC within
or outside India. Recently, B&W has formed a joint venture with Thermax Ltd. to supply B&W boilers
of all types in India as Thermax Babcock & Wicox Ltd. This company has supplied the FBC boilers to
Kanoria Chemicals, Renukoot and Central Pulp Mills, Surat.

Currently most Indian oil refineries are planning to set up refinery residue fired captive power plants.
Foster Wheeler is the only experienced pet-coke fired CFBC supplier in India, currently. However with
pet-coke, IGCC is also techno-economically competitive with FBC. Due to this Essar Oil, had floated
an open tender for their proposed power plant with options both for FBC & IGCC. The bidders include
IHI, Snamprogetti for IGCC and Foster Wheeler, Lurgi for FBC. Other PSU oil companies are
planning on similar lines. HPCL’s proposed refinery at Bhatinda in Punjab plans to go for IGCC.

CFBC Circulating Fluidized Bed Combustion Boiler

GMDC Akrimota
Crushed Lignite fuel (-6mm size0 from the outlet of Lignite Bunkers (2Nos.) is fed into the boiler
belt feeders, one each located below the bunker bottom on either side of the Boiler. Belt feeders
feed the fuel subsequent to the associated drag link conveyors 2 outlet are connected (Total 4Nos)
to the ash return pipes of the cyclones. (Ash return pipes re-circulates back the unburden fuel
escaping from the combustion area in 1st pass collected in the siphon seal below the cyclone
bottom). Lime dust (300m - 750m)- to remove Sulphur in the fuel (called sorbent) is also dozed
pneumatically into each of the ash return pipe (4nos. ash return pipes) along with the lignite before
entering the Fluidized bed.

There is a separated Lime stone storage, milling, lime dust storage and dozing system for the
station.

The siphon / loop seal is located at the bottom of each of cyclone separator. Above fuel and lime
dust sorbent mixture fed on to the inert bed fill (sand / ash) is kept in a fluidized state by admission
of hot primary air from the bottom of the furnace through an array of vertical air nozzles
(1624nos.). The unburned fuel particles carried away by the flue gas gets collected in the cyclone
separator 92nos.) is re-circulated back to the furnace by the fluidizing air admitted at the bottom of
the siphon seal from the discharge of Fluidizing Air fans (3Nos.) which improves the thermal
efficiency.

There are 8nos of HFO burners located on the periphery of the furnace above the fuel bed all
located at the same elevation 11.2M. (3 Front wall, 2Nos each LHS, RHS, 1 No. Rear) The
secondary air admitted through 16 nozzles (1 each on either side of the burner - Front-6 N0s.,
4RHS& LHS, 2 Nos Rear side) location all at same elevation (13.2M) around the furnace above the
oil burners supplements air for combustion. The staged admission of primary and secondary air
enables to control the NoX emossion.

Bed ash collected at the furnace of the furnace is removed through 4 No. L valves. Out let of the 2
L Valves is fed into 1No. ash cooler. There are 2 such ash coolers installed below the furnace. The
coarser ash is evacuated to the drag link conveyor below the ash cooler, which is subsequently fed
to trolley-mounted vessel. These vessels are to be removed for disposal by road. Lighter Bed ash is
fed into the Bed ash evacuation system by Ash Handling package. The ash cooler uses Desalinated
water in closed loop cooled by filtered seawater with the help of plate heat exchangers.

The intermediated panel on the top of furnace divides the flue gas at the top out let of in to two
streams. The flue gas then enters tangentially into the inlet of two cyclone separators located
between the first & second pass of boiler. The swirl created facilitates the fall of unburned fuel
particles into the siphon seal where from it is re-circulated back to the furnace. SH-4 & RH-2
(omega panels) are positioned horizontally one above the other in the below the intermediated
panel.

The outlet of the cyclone separator enters the 2nd pass where SH-5, SH-3, RH-1 & Economizer
coils are arranged from top to bottom in a horizontal fashion. While the steam cooled front wall
panel and the hanger tubes act as the SH-1 the side, roof and rear of 2nd pass act as SH-2. The flue
gas from the exit of the eco-coil is admitted into the Tubular Air Pre Heater. The TAPH heats up
primary & secondary air from the outlet of the respective fans. The ash collected at the bottom of
the 2nd pass hopper is recycled to the furnace bed ash.

The start stabilization is achieved by HFO firing with the help of High Induction ARC igniters.
There is a separate fuel oil unloading, storage, heating and pumping station with storage facility for
LDO (1 X 500KL) and HFO (2 X 1500KL)

The flue gas from the outlet of TRPH enter the ESP in two passes having 7 cells per each pass. The
flue from ESP is pushed vent into 130m high RCC chimney by ID fans.

The drum is located at 51 M level . Lignite crushed by (Material Handing scope) fed into bunkers
(2nos/ boiler)LOCATED IN CD bay. The lignite from bunker is fed into the siphon seal though
gravimetric, drag like conveyors and chutes.

Lime stone fed into the bunker (20MM size by Material Handing Plant) is crushed to dust by Ball
& Tube mills (2 x 125 TPH) and stored in the lime day bins (2 x 400M3 ) from where it is
conveyed to furnace pneumatically though screw with the help of compressed air.

To protect the interior of the boiler from abrasion at high temperature refractory lining is provided
in the combustor / furnace bottom hopper side walls, furnace outlet, Cyclones and loop, cyclone
inlet / outlet ducts, L-Valve, Ash cooler interior and vent pipe etc.
Salient Data of Akrimota Boiler.

Maake Design & Off shore supply - Alstom Stuttgart- GmbH, Germany. On shore supply &
erection- Alstom Power Boilers -India, Durgapur.

No. of Units 2 x 125 MW

Rating Super Heated Steam405 T/Hr, 138 bar, 538°C.Re Heated Steam378 T/Hr.

Attemperation Super Heated Steam by BFP discharge Tap-off before FRS.(On LHS & RHS inter
connection of SH3 O/L to SH-4 I/L to SH-4 O/L to SH-5 I/L)Re- heated steam: Inter stage tab-off
from BFP(On LHS & RHS inter connection pipes of RH-1 Outlet to RH-2 I/L).

Location of Horizontal Pressure Parts(From Bottom to Top) - 1st Pass: RH2 - SH-4 (OMEGA
PANELS - 10 banks)- - Water Walls- 1st Pass/ combustor Side wall, bottom & Roof &
Intermediate panel dividing the furnace top exit.- SH- 1 Front wall and Hanger tubes of pressure
parts in 2nd pass.- SH-2 - LHS & RHS wall panels- Roof panels & Rear wall panel.- Drum- 51M
Elevation- Front of 1st pass. (Cyclone separator, Primary / secondary scrubbers with phosphate
dozing, CBD,IBD)

Air Pre heater Tubular Air Pre Heater (Flue Gas outside the tubes from 2nd pass outlet)Secondary
Air & Primary Air - Inside the Tubes. (Each 3 pass)

ESP -Passes- 2 Nos.- Filed- 7Nos. per pass.- Bottom Hoppers- 2 Nos./ filled/pass- ( Total 28Nos.)

Lignite flow rate Worst Lignite - 179 T /Hr., Design Lignite- 101.7 T/hr.

Boiler Efficiency ~84%

Combustion Air Fans -SA Fans- 2Nos.- Secondary Air, Burner Air, Seal Air, Ash cooler fan
suction.- PA Fans- 2 Nos.- Primary fluidizing Air for Combustor.- FA Fans - 3 Nos.- Fluidizing air
to cyclone loop seals, Scanner Cooling air.- Ash Cooler Fan - Fluidizing air to Ash coolers (Suction
from SAF discharge before SCAPH)- ID FANS -2 Nos. suction from ESP outlet, discharage to
Chimney.

Advatanges in general of CFBC

1. Low operating temperature in furnace 800-900°C against that of ~ 1300 - 1500 °C in that of
conventional pulverized coal Fired Boiler. Temperature is below the ash deformation/ fusion
temperature(~1100 to 1200°C ) and the ash is remove in the from of dust.
2. Control on NoX formation due to lower operating temperature and staged admission of
combustion air. (NOX generally at higher combustion temperature > 1000°C and in presence of
excess air).

3. Fuel flexibility. Can burn variety of fuel such as coal, lignite and non-conventional fuels like
biomass, petro coke, wood etc.

4. Ability to burn low CV fuel.

5. Addition of Lime as sorbent removes Sulphur at point of combustion / in furnace as calcium

sulphate which can be removed along with bed ash in solid form. This prevents atmospheric
pollution from emissions such as SO2. Sulphur is about 97%.

6. Compact design.

7. No pulverizing pf fuel required. Simple firing process- No fire ball etc.

Disadvantages in general of CFBC

1. Erosion of furnace pressure parts & refractory lining due to abrasion of unburned fuel particles &
ash.

2. Low capacity compared to conventional boiler.

KACHAHH TIDAL POWER PROJECT SALIENT FEATURES

LOCATION
State Gujrat
District Kuchchh
Hansthal creek in the Gulf of
Site
Kuchchh
TIDE
Highest spring tide :7.75 m. Mean spring tide 6.43 m.
Mean neap tide 4.02 m. Mean tide 5.23 m.
Highest water recorded at
7.59 m. Lowest water - 0.40 m.
Kandla
Duration of each tide 12 hrs. 27 min. (Average) Total number of tide 704 (Average)
During the year
MAIN BARRAGE
Location Hansthal creek Length 3.25 km.
Height above deepest 31.5 m. Top level of structure EL. 13.0 m.
foundation
POWER HOUSE
Capacity of
Total installation 900MV 25MV
generating unit
Total number of Single regulated
36 Nos Type of Turbine
Generating unit Adjustable
Runner Diameter Blades bulb Turbine Rated head 8.5 m.
Minimum head 5 m. Maximum head 1.2 m.
Turbine speed 7.5 m. Generator speed 52.6 r.p.m
120 mvA, 6.6
Generation Voltage 600 rpm. Setup Transformer
KV/400KV
Annual Energy 1690 Gwh (1690 x 109 wh)