Fluidized Bed Combustion Technical Paper

DOCUMENT TITLE :
FLUIDIZED BED COMBUSTION

TECHNICAL PAPER
DOCUMENT NO. : WORK ITEM NO. : REV SHEET
A 1 of
House of Steam Engineering 23
CLIENT :
Http://www.hamadaboiler.com
TPC VINA PLASTIC AND CHEMICAL CORP., LTD.
PROJECT TITLE :
“FLUIDIZED- FIRED BOILER MODEL DF22:13FBC”

TECHNICAL PAPER
A Issued for Approval JML
PREP’D CHEC’D APPR’D APPR’D

REV DESCRIPTION DATE
GTS VI
649148923.doc
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House of Steam Engineering DOCUMENT NO. WORK ITEM NO. REV SHEET
Http://www.hamadaboiler.com A 2 of 23
CONTENTS
SECTION TITLE PAGE
(1) INTRODUCTION ON FLUIDIZED BED COMBUSTION TECHNOLOGY 3-6

(2) BOILER GENERAL DESCRIPTION 6 - 10
(3) BOILER TECHNICAL DATA 11 - 12
(4) FUEL 13
(5) COMBUSTION 13
(6) BOILER MASTER AUTO CONTROL, VALVES & GAUGES 13 - 15
(7) WATER LEVEL CONTROL SYSTEM 15
(8) FEED WATER TRANSFER PUMP (2 UNITS PER BOILER) 16
(9) BALANCED DRAFT SYSTEM 16 - 17
(10) ECONOMIZER 18
(11) ASH HANDLING 18 - 20
(12) SMOKE STACK 20
(13) COAL HANDLING & FEEDING SYSTEM (front & rear double feeding) 20 - 21
(14) COMPONENTS & ACCESSORIES 21 - 22
(15) PLATFORM, LADDER, GANGWAYS and RAILINGS 22
(16) ELECTRICAL POWER CONSUMPTION 23
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(1) INTRODUCTION ON FLUIDIZED BED COMBUSTION TECHNOLOGY:
There are several methods adopted for firing solid fuels such as coal, husk, bagasse
etc. The fuels can be hand-fired on static grate of mechanical stokers such as Low Ram,
Chain Grate, Underfeed Stoker, Travel grate, etc., could be used with or without spreader.
Large boilers are fired by pulverized fuels wherein finely ground fuel is burnt in a stream of
air (more like oil), in a special pulverized fuel burner. But today’s cutting edge technology is
“FLUIDIZED BED COMBUSTION”, which was developed about two decades ago and in
perfect harmony with Indonesian Bituminous fine coal.
Solid particles could be moved by fast stream of air. The movement depends on
velocity of air in the medium. If the velocity is too low, air will percolate through the bed
solids. On the other hand, if the velocity is too large, the solids will be pneumatically
transported. If the velocity of the air stream passing through the bed is gradually increased,
a point is reached where individual particles are forced upwards with the rising bubbles, as
the bubble comes out of the bed and burst, these particles are returned back to the bed
causing rapid mixing of particles. The surface is no longer well defined and the bed in this
state is called bubbling bed or FLUIDIZED BED. The fluidized bed exhibits many properties of
liquids such as:
1.1. The bed finds its own level.
1.2. Addition of any solids to the bed is mixed uniformly through out bed.
1.3. Objects can float and sink in the fluidized bed depending upon the density.
1.4. When heat is generated in one part of the bed it is transferred uniformly throughout
the bed.
1.5. Mixing in fluidized bed causes the heat to be rapidly transferred to cooler surfaces
(such as water tubes) immersed in it.
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This phenomenon of fluidized bed has been used in chemical engineering for years,
but its use for combustion of fuel is only two decades old. If the fuel is added continuously
to fluidized bed working at a temperature higher than the fuel’s ignition temperature, the
combustion can be self-sustained. Because of turbulence and rapid mixing, low excess air
(30-40%) is required for complete combustion. Very high heat transfer rates are observed if
some cooling surface is immersed into the bed. It is possible to control the temperature of
combustion at a level much lower than the clinkering temperature (When ash starts
melting), making it safe in operation.
The fluidized bed consists of plenum chamber (air box), an air distributor pipes fitted
with air nozzles, a sand hopper which supports the bed of sand (or ash and foreign matters)
and a high pressure forced draft fan, which is used for bubbling the air through the bed. The
heating surface in the form of bended tubes is partially immersed in the bed. This heating
surface is responsible for maintaining bed temperature below 950°C and generates up to
40-45% of the rated steam output of the boiler.
The fuel, less than 10 mm size, is fed to the bed either with a screw feeder just above
the expanded bed. Secondary air is added at this point, which also helps in spreading the
fuel. For controlling the dust emission from the fluidized bed, we have provided dust-
collecting equipment for cleaning the flue gasses before passing them through the chimney.
HOW IT OPERATES :
When air or gas is passed through an inert bed of solid particles, such as sand,
supported on a fine mesh or grid, the air, initially, will seek a path of least resistance and
pass upward through the sand. With further increase in the velocity, the air starts bubbling
through the bed and the particles attain a state of high turbulence. Under such condition,
the bed assumes the appearance of a fluid and exhibits the properties associated with a
fluid and hence the name “FLUIDIZED BED”.
　　　　　　　　　　　　
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MECHANISM OF FLUIDIZED BED COMBUSTION (FBC):

If the sand in fluidized state is heated to ignition temperature of the fuel and fuel is
injected continuously into the bed, the fuel will burn rapidly and the bed attains a uniform
temperature due to effective mixing. This, in short, is “FLUIDIZED BED COMBUSTION”.
While it is essential that temperature of bed should be at least the ignition
temperature of fuel, it must never be allowed to approach adiabatic combustion
temperature (1300°-1500°C) to avoid melting of ash. The combustion must be carried out
essentially at a temperature below ash fusion temperature. This is achieved by extracting
heat from the bed through heat transfer tubes immersed in the bed as well as through
furnace water walls.
If the gas velocity becomes too high, the particles are entrained in the gas stream
and are lost. Hence, to sustain stable operation of the bed, it must be ensured that gas
velocity maintained between minimum fluidization velocity and particle entrainment
velocity.
ADVANTAGES OF FBC BOILERS:

1. Considerable reduction in boiler size is possible due to high heat transfer rate over a
small heat transfer area immersed in the bed.
2. Low combustion temperature of the order of 750°-900°C facilitates burning of fuel with
low ash fusion temperature, prevents NOх facilitates, reduces high temperature
corrosion and erosion, and minimizes accumulation of harmful deposits due to low
volatilization of alkali components.
3. High sulfur fuels can be burnt efficiently without much generation of SOх by feeding
limestone continuously with the fuel.
4. The unit can be designed to burn a variety of fuels including low grade fuels, like
floatation slimes and watery rejects, without much sacrifice in operating efficiency,
because only about 1% by weight of carbon content in the bed can sustain the
fluidized bed combustion.
5. High turbulence of bed facilitates quick start-up and shut down.
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6. Full automation of start-up and operation using simple reliable equipment is possible.
7. Inherent high thermal storage characteristics can easily absorb fluctuations in fuel feed
rate.　　　　　　　　　　　　　　
8. Ash are generally dry and non-adhering and possess self-cleaning action when passing
through fireside tube banks, thus soot blowers are not required.
9. Fine coal of 0-15 mm in size can effectively be used.
10. It prevents the formation of sticky deposits on the fireside of the tubes because of
lowering of ash fusion temperature by sodium components of ash due to low bed
temperature.
(2) BOILER GENERAL DESCRIPTION:
The HAMADA Coal-Fired Fluidized Bed Steam Boiler Model DF22-13 FBC is a natural
circulating type water tube boiler with an upper steam drum and a lower mud drum
longitudinally arranged. The tubes are inserted and welded onto it. It is also of balanced
draft system. It consists of two main parts: the upper main pressure vessel and the lower
Fluidized Bed combustor.
The boiler is of welded (main pressure vessel and in-bed combustor) construction
throughout and is designed and engineered to the relevant China Boiler Code with
equivalent to the American Society of Mechanical Engineers (ASME) Code (Power Boiler
Section 1, 1992) specifications. The pressure vessel is x-rayed and stress relieved as required
for Fusion Welded Pressure Vessels.
The front part of the heating surface block of the boiler consists of water cooling
walls and connected from the lower header to the main upper drum for absorbing the
radiant heat of combustion. The rear part is a bundle of convection tubes which connects
the upper and lower drum. The heating block is lined with mattress of insulating materials
and covered by outside cladding.
The lower Fluidized Bed Combustor consists of bended and vertically arranged rows
of in-bed tubes connected to a lower and upper header. The upper header is connected to
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the main upper drum. Majority of the steam generation emanated from these in-bed tubes.
It has protective fins to guard against abrasion.
The flue gas passes transversely through the convection tube bundle with successive
paths and then through the finned cast iron economizer separately arranged at the rear of
the boiler and through the multi-cyclone dust collector, wet scrubber and exhausted to the
chimney.
　　　　　　　　　　　　　　　　
2-1: BOILER FEED WATER SUPPLY SYSTEM:
The feed water from the feed water tank is pumped to the boiler by the feed water
pumps. Two water pumps are used. One is running and the other is standby. Feed water as
per the recommended specifications should be fed to the boiler.
2-2: BOILER WATER CIRCULATION SYSTEM:

The boiler water circulation system consists of in-bed tube bundle, water walled
furnace, and water tube boiler. The in-bed tube bundle and waterwall tubes have a self-
adjusting circulation pattern with connecting external downcomers and upraisers.
A portion of water that circulates is evaporated and steamed. Water mixture rises up
into the upraiser header. This mixture of steam and water is taken to the boiler upper shell
where steam is separated to the water with the incoming feed water for further circulation.
The hot gas passes through a series of four (4) bundles of water tubes. Water circulates by
natural circulation and steam separates at the boundary of water and steam space.
2-3: FIRING SYSTEM:

The coal is burnt in a fluidized bed combustor. A high pressure FD fan is used to
supply the fluidizing air. Inert material such as silica sand should be used as bed material.
The combustion air is provided at three (3) points. Primary air distributor, secondary air in
the free board zone and third a short distance above the free board close to the waterwalls.
This ensures complete combustion of suspended coal particles.
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The Fluidized Bed Combustor is lined with refractory bricks and insulation up to the
header of the boiler waterwalls. This arrangement helps in effective cooling of the flue gases
and maintaining a furnace temperature. The firing system is capable of operating up to 33%
of the MCR capacity.
2-4: COMBUSTOR START UP SYSTEM:

Fluidized bed boiler start up can be done by spreading the fire throughout the bed,
mixing hot charcoal into the sand by giving occasional push with high pressure air. The
temperature of the entire sand bed will rose up to 500 oC at which point fuel is added to the
bed and the combustion will become self-sustaining. This procedure is quite simple but
requires certain amount of training to the operators.
2-5: FUEL HANDLING AND FEEDING SYSTEM:

Hamada Boiler provides complete coal handling and feeding system. Fine coal of 0-
15 mm size is being unloaded to a hopper drops onto the sharp angle elevating conveyor
and cdonveyed horizontally to the 10 M3 capacity vertical coal storage silo. The coal in turn
is being fed to the furnace through a 2-step modulating speed rubber belt conveyor. At the
feeding mouth, the coal separates into two (2) chutes with distance of one meter and drops
into the fluid bed. The rate of fuel feed to the boiler is modulated automatically to maintain
a constant and steady pressure of steam. Manual variable speed of the screw conveyor is
also provided.
2-6: COMBUSTION AIR SYSTEM:

Cold atmospheric air is supplied to the combustor in three streams; primary,
secondary and tertiary air. The primary air is supplied through nozzles located at the top of
the pressurized pipe air chamber. Secondary air nozzles located at a little distance above the
fluid bed to assist combustion. Tertiary air injection is above the freeboard zone of upper
waterwall.
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As the coal is fed to the fluid bed furnace, majority of it burns inside the fluidizing
bed which in turn releases large amount of heat. The in-bed water tubes placed inside the
fluid bed absorbs large amount of heat to maintain the bed temperature in safe limits. A
substantial portion of steam generation takes place in this area.
Secondary air is given in free board zone to burn the volatile matter. Flue gases
leaving the combustion zone transfer heat by radiation to the water wall tubes. The gases
then transfer heat by non-luminous radiation and convection to the water tube bundles.
The gases pass through the waterwalls and through the four (4) bundles of water tubes.
There is no 180 degrees turn of flue gas.
The said ash falls down by gravity to the conical ash collection pit below the boiler.
The gases cool down after passing through the tube bundles, and goes out the economizer.
Cooled gas flows to the dust collection system. The ash is then collected in the hopper
provided underneath the BAG FILTER.
An ID fan is provided in the flue gas stream after the BAG FILTER dust collector in
order to produce the necessary draft for maintaining the furnace at slightly negative
pressure.
The damper at inlet of ID fan is adjusted AUTOMATICALLY to maintain the furnace draft at
the constant level. Finally, the flue gas carrying some ash that escapes from the multi-
cyclone separator passes through a Wet Scrubber/Spray to trap the escaped ash. A chimney
of 24 meters height is provided to vent the gases to atmosphere.
2-8: VALVES AND INSTRUMENTS:

The boiler is provided with valves, controls and instrumentation. This includes the
fitting and mountings required for the pressure part, as well as those required for the safe
and 　　　　　　　　　　　　　　　　
successful operation of the system offered. Premium and high quality valves, for Blowdown
and other piping valves are being used.
2-9: CONTROL PANEL:

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The instrument control panel is a free standing self supported type. This is provided
with necessary alarms, hooter and indication lamps. The necessary starters for electrical
motors are located in the same panel. All starters and contactors are of premium Japanese
and/or European brands.
2-10: ASH HANDLING:

The fly ash generated after combustion of coal is collected in the various ash
collection points. These are 1; below the boiler water tube bundles, 2; below the
economizer assembly, 3; below the multi cyclone, 4; above coal silo . Ash from 1. 2, 3 & 4.
Will be delivered to Ash silo.
2-11: BED MATERIAL DRAINING SYSTEM:

When coal burns in the fluid bed, some impurities such as stones, soil, foreign
matters, etc. accumulated in the fluid bed. The HAMADA Fluidized Bed Boiler incorporates a
unique CIRCULATING SAND BED SYSTEM. This system is designed in order to clean the inert
material with its impurities from the fuel. Cleaning can be done automatically WITHOUT
SHUTTING DOWN the boiler. By just opening the chute lever, a certain amount of bed
materials falls and passes through an eccentric separator/vibrator that separates the pure
sand to the impurities. The clean sand automatically circulates back to the combustion
chamber, while the impurities falls onto dirt bin.
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(3) BOILER TECHNICAL DATA:

MODEL : DF-22-13-FBC
BOILER TYPE : BI-DRUM WATER TUBE
RATED STEAM OUTPUT : 22,000 KG/H
MAX. WORKING PRESSURE : 13 KG/CM2
CONSTANT STEAM PRESSURE : 10 KG/CM2
FEED WATER TO THE ECONOMIZER : 104 oC (from Deaerator)
STEAM QUALITY : SATURATED
FEEDWATER TEMPERATURE : 100-120 C
AIR TEMPERATURE : AMBIENT 25-30 C
EXHAUST GAS TEMP. : 160-180 C
NET EFFICIENCY : 85% at 90% load

: 83% at 60% load
UPPER DRUM MEASUREMENT : L= 9756 MM

: D= 1036 MM
: T= 18 MM
MATERIAL : ASME SA-285
LOWER DRUM MEASUREMENT : L=4880 MM

: D=1036 MM
: T= 18 MM
BOILER TUBES DETAILS : D= 51 MM

: T= 3.5 MM and 5.5 mm
HEADER DETAILS : D= 219 MM

: T= 8.00 MM
WEIGHT : 30 TONS
3.1. FLUIDIZED BED COMBUSTOR ASSEMBLY:
Pre-assembled and hydro-tested at our factory with headers, bended cooling tubes
with protective fins, for assembly at site
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3.2. HEADERS, DOWNCOMER & UPRAISER TUBES:
Pre-bended at our factory for assembly at site in accordance with material quality
CODE SA-210 (ASME REFERENT VIII-B)
3.3. FLUIDIZED BED HIGH PRESSURE AIR HEADERS:
Pre-fabricated at our factory, complete with zig-zag configuration high pressure air
header, air box and accessories
3.4. FLUIDIZED BED HIGH PRESSURE AIR NOZZLES:
Screw-type for easy assembly and dismantling, hexagonal with concave head design,
made from hi-heat resistant cast iron (until 1300oc if the buyer order ignitial start up
burner)
3.5. MAIN BOILER REFRACTORIES, FIRE CEMENT & CASTABLES:
Consisting of fire bricks sk-34 & sk-36 (until 1700 oc in side the furnace) insulating
bricks, mortar clay, castable, fire cement, rockwool insulation, etc.
3.6. CIRCULATING SAND ECCENTRIC SEPARATOR:
Pre-assembled standard circle type, complete with sand belly, frame, chute, driven
by 1.5 kw motor (top hopper made by stainless steel)
3.7. SILICA SAND RETURN BLOWER:
Pneumatic type, ss pipe with helical fins, driven by 1.5 kw motor, with stainless
bended return pipe
3.8. BOILER STEEL STRUCTURES, STIFFNERS, ETC.:
Pre-fabricated, complete with structures for boiler mounting, with base plates, cross
bracings, stiffeners
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(4) F U E L:
QUALITY : VIETNAM ANTHRACITE COAL
SIZE : 0 – 15 MM (FINE COAL)
CALORIFIC VALUE : 6000 – 6700 KCAL/KG
VOLATILE MATTER : 3.1 – 9.0 %
ASH CONTENT : 9.7 – 20.2 % MAX.
SULFUR CONTENT : 0.6 - 0.77 %
MOISTURE CONTENT : 2.8 – 16.3 %
FIXED CARBON CONTENT : 80.5 – 85.7%
BULK DENSITY : 800 – 929 Kg/m3
(5) COMBUSTION:
SYSTEM : FLUIDIZED BED

FURNACE HEAT RELEASE : 310,000 K/cal/M3
INERT MATERIAL : SILICA SAND
SIZE : Si 02-99 – 99.5% #2 SM-2
PRESSURIZED AIR DISTRIBUTION : BY CAST-IRON HIGH PRESSURE
NOZZLES HEXAGONALLY DESIGNED
　　　　　　　　　　　　　　　　
(6) BOILER MASTER AUTO CONTROL, VALVES & GAUGES:
Control and operation of the entire boiler is being controlled from the main control panel.
The water level, as well as the boiler pressure is being managed by the master auto control.
It is all interlocked to function in an auto mode.
The boiler pressure is being controlled by a SIEMENS PLC S7-300 CONTROL SYSTEM.
When the pressure moves either way, through a pressure transmitter, the controller
activates the FDF and 2nd FDF to either open or close, depending on the movement of
pressure. It also activates the fuel screw feeder to regulate the fuel intake. It also manages
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the FBC Bed temperature. The furnace negative pressure is the one sending signal to the
IDF.
6.1. ACCESSORIES:
 MAIN BOILER POWER PANEL:
Self standing, with complete instruments, magnetic contactors, relays, switches,
circuit breakers, thermal overload, gauges, pilot lights; integrated into one-point
power system, using premium brands
 CONTROL AND AUTOMATION :
1. Such as Fuji, Mitsubishi, Yokogawa, etc.
2. Siemens plc s7-300 control system complete with CPU,
3. 17 screen monitor, Scada etc., for boiler management control
4. (press, water level,)to function in automatic mode,
5. Including modulating feeder, steam pressure control,
6. Water level control and modulating dampers, furnace.
7. Temperature control with screw feeder, burn back
8. Temperature control with solenoid valve and water spray
9. System in side the pipe feeder, emergency flue gas temperature Control
(TICA) inside furnace.
10. Water level gauge and control with bi-colour li and include CCTV camera
(day-night).
11. Boiler pressure gauge and control.
12. Furnace pressure gauge and control id damper.
13. Explosions door
14. Dust roof standard IP 21
 MAIN STEAM GATE VALVE DN 200 PN 25

 MAIN STEAM CHECK VALVE DN 200 PN 25
 SAFETY VALVES DN 80 PN 16
 MANUAL TYPE BLOWDOWN VALVES PN 16
 OTHER VALVES SUCH AS CHECK VALVES, BALL VALVES, GATE VALVES, ETC.
PN16
 STEAM FLOWMETER, ORIFACE TYPE, Yokogawa
 WATER FLOW METER, VORTEX TYPE, Yokogawa
 O2 METER MONITORING COMPLETE WITH ACCESSORIES
 ELECTRICAL WIRES & CABLES WITHIN THE BOILER ISLAND USING HIGH
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QUALITY WIRES & CABLES INCLUDING TRAYS SURROUND BOILER ISLAND

 PIPING MATERIALS & PARTS:
Such as blowdown piping, feed water supply line, flanges, elbows, tees,
instrument piping, economizer by-pass line, etc include all counter flange ansi
standard
6.2. SEPARATE ALARM PANBEL TO BE INSTALLED AT THE BOILER CONTROL ROOM
 Indicate Alarm of serious boiler operation
 Indicate IDF,FDF,BFP Thermal trip
 Indicate other Motors’s thermal trip
 Indicate FBC bed temperature
 Indicate Furnace temperature
 Alarm of Drum level H, L, LL
 Alarm of Drum pressure H, L
 Alarm of Coal Silo H and L
 Alarm of coal feeder(in case coal flow stop)
 Alarm of H , L , of feed water tank
 Alarm Furnace pressure H and L
(7) WATER LEVEL CONTROL SYSTEM:
When the water level goes to LOW, the low water level activates and the system
automatically shuts off until the water level goes back to normal. The system starts in
sequence automatically when the water reached the normal level.
The transmitters transmits signal to servo motor controller. In turn, the regulating valve at
the servo motor will open/close according to water level condition. The sequence repeats as
the situation call for it. The water level control system are composed of the following
accessories:
SERVO MOTOR CONTROLLER

LOW AND HIGH WATER ALARM SENSOR
LOW AND HIGH WATER ALARM BELL
WATER LEVEL SIGHT GLASS
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(8) FEED WATER TRANSFER PUMP (2 UNITS PER BOILER):
Constructed as centrifugal pump mounted on a console with manometer, valves with water
supply piping’s. It has an electrical turn-over switch for Pump 1 & Pump 2, with electrical
wiring, driven by an electric motor, ready for operation. It is suitable for water temperatures
of up to 105 C at varying gravity heights.
8-1: SPECIFICATION:
FEED WATER PUMP : 2 units
MAKE : GRUNDFROS
TYPE : CENTRIFUGAL
CAPACITY : 24.2 m3/h
HEAD : 179 M
INSTALLED MOTOR : 22 KW
POWER SUPPLY : 380V , 50 Hz.
8-2: ACCESSORIES:
PRESSURE GAUGE : 2 PCS.
COUPLING PARTS : 2 PCS.
STOP SLIDES ON SUCTION SIDE : 2 PCS.
NON-RETURN VALVES : 2 PCS.
(9) BALANCED DRAFT SYSTEM:
9-1: INDUCED DRAFT FAN:

Induced Draft Fan, driven by 90 KW electric motor, complete with body, impeller,
gearbox, motorized damper and water cooling system
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CAPACITY : 41,536 m3/hr

STATIC PRESSURE : 3,100 PA
MAX. FLUE GAS TEMP. : 350 C
ELECTRIC MOTOR : 90 KW
ROTATION SPEED : 1450 PRM
POWER SUPPLY : 380V, 50 Hz, 1450 rpm
9-2: PRIMARY FORCED DRAFT FAN:

High pressure Primary Forced Draft Fan, driven by direct coupled 90 KW electric
motor, with built-in silencer and motorized damper system
CAPACITY : 16,883 m3/hr
AIR TEMPERATURE : AMBIENT 30 C
ELECTRIC MOTOR : 90 KW
ROTATION SPEED : 2900 RPM
9-3: SECONDARY OVERFIRE FAN:

Secondary over fire forced fan, driven by direct- coupled 18.5 KW electric motor with
built-in silencer and motorized damper system
CAPACITY : 6,589 M3/hr
AIR TEMPERATURE : AMBIENT 30 C
ELECTRIC MOTOR : 18.5 KW
ROTATION SPEED : 2900 RPM
　
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(10) ECONOMIZER:
Constructed as a packaged unit, it is of cross flow type made from cast iron finned tubes. It is
of assembled form and for assembling at site. It has a body with structural frame. It has also
a bottom chute for ash discharge. complete with pipings, safety valve and ash discharge pit
with piping and online safety valve include rotary valve discharge ash.
The exiting flue gas from the boiler rear passes through a series of cast iron finned tubes. In
so doing, the energy from the still hot flue gas is being transferred to the water inside the
finned tubes, thereby raising the temperature of the feed water to 100 C.
SPECIFICATION:
TYPE : CROSS FLOW
MATERIAL : CAST IRON
LENGTH OF FINNED TUBE : 2,000 MM
TOTAL SURFACE HEATING AREA : 295.0 m2
EXIT WATER TEMP. : 190 C
(11) ASH HANDLING

11-1. MULTICYCLONE
100 pcs. Multi-cyclone dust collector material cast iron, drop pressure 90 mm
h20, eff 90%, paricle size collect > 8 micron complete with body, frame, 2 branches
outlet pipe with sliding gate under rv, structural supports, stiffners, ash discharge pit
with rotary air lock valve, driven by 1.5 kw electric motor
SPECIFICATION:
NO. OF MINI CYCLONE : 100 PCS.
MATERIAL : CAST IRON
PRESSURE DROP : 90 mmWG
EFFICIENCY : 90%
SIZE OF PARTICLES COLLECTED : >8 micron
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11.2. VENTURY WATER SPRAY

Venturi-type water spray/scrubber system and accessories, hour glass configuration,
stainless water nozzles, stainless agitator drum and stainless pump 30 m3/hr driven
by 4 kw electric motor
SPECIFICATION:
DIAMETER : 2000 MM
HEIGHT : 6000 MM
FLUE GAS INLET VELOCITY : 52 M/S
WATER VOLUME CIRCULATED : 30 m3/hr
11.3. EP ASH AIR COMPRESSOR PULSE CONVEYOR WITH ASH BIN

 At the bottom of the multi cyclone it is equipped with the compressor air pulse
jet system, ash bin with pneumatic conveyor to send fine ash to the ash silo
made of concrete.
 inside ash silo, bag filter is provided to release excess air, also fluidizing system is
adopted to keep the ash moving at all time to prevent coagulation.
 automatic discharge valves are installed to discharge ash to the ash removal
vehicle.
included:
- air pressure tank.
- ash bin pump (pneumatic pump)
- ash delivery pipe.
- 35 m3 ash silo
- bag filter (releasing the excess air)
- fluidizing system (ash inside silo is kept fluidizing always)
- automatic discharging system to the truck.
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11.3. DUSTING FREE SYSTEM
Completed dusting free system included exhaust fan, bag filter, and air ducting pipe
from crusher, service cyclone (25m 3), box under multi-cylon, receiving hope to
fan and bag filter
(12) SMOKE STACK
The smoke stack (chimney) is of self-standing type. It is pre-rolled and welded at our factory
and delivered to the site on a 4.0m x 1.0m section. It then being joined and welded at site. A
catwalk is provided in case of flue gas sampling. A ladder is also provided for easy access to
the catwalk. It is being painted with thermal resistant paint. - temp spec 540OC
28-meter high chimney, 1.5 m dia., with climbing ladder 9 meter (flow TPC spec), catwalk,
base plate, inspection platform, and ash cleaning access door with 2 sample point and water
spray nozzle facilities. material SS 41
12-1: SPECIFICATION:
TYPE : SELF STANDING
DIAMETER : 1500 MM
HEIGHT : 24000 MM
MATERIAL : SS-41
PAINTING : THERMAL RESISTANT PAINT
　
(13) COAL HANDLING & FEEDING SYSTEM: (front & rear double feeding)
Coal is being fed to the boiler in a series of equipment as specified in the scope of
supply. First, the coal from the storage area is being dumped onto the coal receiving hopper
and conveyed to a COAL CRUSHER MACHINE and drops directly to the hopper of the
motorized coal conveyor/lifter. The vertical conveyor/lifter then lifts up the coal onto the
coal silo. From there, the coal is being fed to the boiler by means of a Screw coal feeder.
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TECHNICAL PAPER
The speed of which is managed by the main auto control.

Feeding point will be front & rear (2 places) and each drop chute end will have
pneumatic high pressure air blow system to spread coal to the wide area of the bed.
13-1. COAL RECEIVING HOPPER,
Coal receiving hopper, 40 m3 capacity, with in sided divider, complete with double
discharge screw conveyor, with frame, structure, climbing ladder & working platform
13-2. TURBO FAN AND HAND DOOR TO SERVICE THE PIPE FROM SREW
13-3. PROVIDE SIREN CONNECT COMMON ALARM

Conveyor to boiler when the coal feeder clogging
13-4. LIMESTONE SILO CAP 1M3 AND FEEDING SYSTEM (SREW WITH MOTOR)
In case the sulphur content of coal becomes high
(14) COMPONENTS & ACCESSORIES:
14-1 CHEMICAL DOSING PUMP WITH BRINE TANK

Cap 10 lit/hr pressure 10 bar (lp)
14-2 FLUE GAS AIR DUCTS FROM BOILER TO CHIMNEY, COMPLETE

With flanges, joints, structural supports, stiffeners and servicing access doors,
1 MH/HH every ducting
14-3 HIGH HEAT RESISTANT PAINTING MATERIALS FOR HOT PORTIONS

AND LOW-HEAT PAINTS FOR OTHER PAINTING PORTIONS
(Blue color for economizer, silver for chimney, yellow for ladder railing, grey for coal
handing)
14-4 INSULATION MATERIALS FOR BOILER AS FOLLOWS:
For boiler body, fbc furnace, waterwall, downcomer and upraiser tubes, downcomer
headers, blowdown pipes, flue gas duct up to economizer only. Flue gas duct
insulation from economizer to chimney with height of two (2) meters from ground
level
14-5 ALL OTHER RAW MATERIALS NEEDED

Such as steel plates, angle bars, channel unp, round bars, corrugated plates; bolts,
nuts, packings, etc.
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TECHNICAL PAPER
14-6 STEAM HEADER, COMPLETE WITH FLANGES PER

Customer’s requirements, pressure gauge, strainer & structure.
Note: valves are not included.
14-7 CAMERA CCTV BUILT IN SCADA MONITOR (COLOR FULL)

Install in coal storage and boiler room
14-8 STEAM PIPE FROM BOILER ROOM TO STEAM HEADER

Steam pipe, insulation and clading by aluminium inlet valve of steam header DN 200
14-9 HIGH PRESSURE CHEMICAL PUMP WITH TANK AND ACCESSORIES
14-10 MONITOR LOCATED DISTANCE FROM

Boiler room, wiring for 10 points with repeater
14-11 IGNITION BURNER

Burner, oil pump and oil tank 5m 3, piping and control box hi-heat resistance air
dusting pipe with insulation hi-heat resistance air nozzle and distributor
(15) PLATFORM, LADDER, GANGWAYS and RAILINGS:
Platform around the boiler is provided for easy access to all instruments, meters and
gauges. It also helps the operator to easily check every component around the boiler.
Ladders, gangways and railings around the boiler is also provided.
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TECHNICAL PAPER
(16) ELECTRICAL POWER CONSUMPTION:
INDUCED DRAFT FAN : 90 KW

SERVO MOTOR FOR IDF DAMPER : 1.1 KW
PRIMARY FORCED DRAFT FAN : 90 KW
SERVO MOTOR FOR PFDF DAMPER : 1.1 KW
SECONDARY OVERFIRE FAN : 18.5 KW
FEEDWATER SUPPLY PUMP : 11 KW (x2)
COAL CRUSHER : 11 KW
FLAT BELT CONVEYOR : 3 KW
MOTORIZED VERTICAL COAL CONVEYOR : 3 KW
PRIMARY STEP COAL SCREW FEEDER : 2.2 KW
SECONDARY STEP COAL SCREW FEEDER : 2.2 KW
ECCENTRIC/VIBRATING SAND CLEANER : 1.5 KW
SCRUBBER CIRCULATING DIRT PUMP : 4 KW
MULTI-CYCLONE DISCHARGE ROTARY VALVE : 1.1 KW
CONTROL PANEL POWER : 0.5 KW
Total : 251.2 KW

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DOCUMENT TITLE :

FLUIDIZED BED COMBUSTION

FLUIDIZED BED COMBUSTION

A Issued for Approval JML

PREP’D CHEC’D APPR’D APPR’D

FLUIDIZED BED COMBUSTION

SECTION TITLE PAGE

(1) INTRODUCTION ON FLUIDIZED BED COMBUSTION TECHNOLOGY 3-6

FLUIDIZED BED COMBUSTION

(1) INTRODUCTION ON FLUIDIZED BED COMBUSTION TECHNOLOGY:

FLUIDIZED BED COMBUSTION

FLUIDIZED BED COMBUSTION

MECHANISM OF FLUIDIZED BED COMBUSTION (FBC):

ADVANTAGES OF FBC BOILERS:

FLUIDIZED BED COMBUSTION

(2) BOILER GENERAL DESCRIPTION:

FLUIDIZED BED COMBUSTION

2-2: BOILER WATER CIRCULATION SYSTEM:

2-3: FIRING SYSTEM:

FLUIDIZED BED COMBUSTION

2-4: COMBUSTOR START UP SYSTEM:

2-5: FUEL HANDLING AND FEEDING SYSTEM:

2-6: COMBUSTION AIR SYSTEM:

FLUIDIZED BED COMBUSTION

2-8: VALVES AND INSTRUMENTS:

2-9: CONTROL PANEL:

FLUIDIZED BED COMBUSTION

2-10: ASH HANDLING:

2-11: BED MATERIAL DRAINING SYSTEM:

FLUIDIZED BED COMBUSTION

(3) BOILER TECHNICAL DATA:

NET EFFICIENCY : 85% at 90% load

UPPER DRUM MEASUREMENT : L= 9756 MM

LOWER DRUM MEASUREMENT : L=4880 MM

BOILER TUBES DETAILS : D= 51 MM

HEADER DETAILS : D= 219 MM

3.1. FLUIDIZED BED COMBUSTOR ASSEMBLY:

FLUIDIZED BED COMBUSTION

3.2. HEADERS, DOWNCOMER & UPRAISER TUBES:

3.3. FLUIDIZED BED HIGH PRESSURE AIR HEADERS:

3.4. FLUIDIZED BED HIGH PRESSURE AIR NOZZLES:

3.5. MAIN BOILER REFRACTORIES, FIRE CEMENT & CASTABLES:

3.6. CIRCULATING SAND ECCENTRIC SEPARATOR:

3.7. SILICA SAND RETURN BLOWER:

FLUIDIZED BED COMBUSTION

SYSTEM : FLUIDIZED BED

FLUIDIZED BED COMBUSTION

 MAIN STEAM GATE VALVE DN 200 PN 25

FLUIDIZED BED COMBUSTION

QUALITY WIRES & CABLES INCLUDING TRAYS SURROUND BOILER ISLAND

(7) WATER LEVEL CONTROL SYSTEM:

SERVO MOTOR CONTROLLER

FLUIDIZED BED COMBUSTION

(8) FEED WATER TRANSFER PUMP (2 UNITS PER BOILER):

(9) BALANCED DRAFT SYSTEM:

9-1: INDUCED DRAFT FAN:

FLUIDIZED BED COMBUSTION

CAPACITY : 41,536 m3/hr

9-2: PRIMARY FORCED DRAFT FAN:

9-3: SECONDARY OVERFIRE FAN:

FLUIDIZED BED COMBUSTION

(11) ASH HANDLING