• Types of Boilers

• Concept of Fluidization
• FBC Boilers: Introduction, Types and Need
• CFBC Boilers: Working Principle, Constructional
Features, GA, Layout and Operating Parameters
• Some Great Examples
• BHEL’s Pain: A Case Study
• Pulverized Fuel Fired Boilers
• Fluidized Bed Combustion
• When an evenly distributed air or gas is passed
upward through a finely divided bed of solid particles
such as sand supported on a fine mesh, the particles
are undisturbed at low velocity. As air velocity is
gradually increased, a stage is reached when the
individual particles are suspended in the air stream –
the bed is called “fluidized”.

• And the process is called “FLUIDIZATION”

Solid Particle

Air / Gas
 FLUIDISED BED
BOILER
When Buoyancy Force

Buoyancy Force
balances
Gravity Force
Gravity Force

FUEL AIR
A Bed of Solid Particles exhibit the FLUIDISED BED BOILER

properties of a FLUID namely:

 Lighter objects float heavier ones sink
( Fixes Fuel Size)
 Pressure drop is Bed Height (Fixes
Fan Power)
 Horizontality maintained (Fixes Ash
Disposal Mechanism)
hence termed as Fluidized Bed FUEL AIR
ASH
The Bed of solid particles have to be retained at
that size:
FLUIDISED BED BOILER
Combustion Temperature has to be well below ash
fusion temperature
Heat transfer walls are enclosed
Ash does not fuse - no slagging
Heat transfer by Conduction, Convection
Fuel size up-to 15mm - No PULVERISING
Ash soft amorphous state - less erosion
FUEL AIR
ASH
 FLUIDISED BED

The Bed of solid particles have to be Fluidized - Velocity Profile

uniform velocity:
A nozzle type Air Distributor provided
Uniform Air/Oxygen availability across Air distributor
the entire Bed cross section - one
pre-requisite for good combustion

AIR
When Fuel is injected into a Fluidized Bed of FLUIDISED BED BOILER
solid particles which is heated to Ignition
Temperature of Fuel, it burns imparting heat
to the entire bed

Fuel Combustion takes place due to the

heat available in the Bed Ash - millions of
IGNITORS
Fuel of any Quality can be fired
FUEL
AIR
ASH
 FLUIDISED BED BOILER
Combustion of Solid Fuel leaves behind
Ash. Finer fraction carried by flue gas,
coarser fraction replenishes the bed solid
inventory and excess is drained out by
drain pipes

Ash is dry and granular and is easily

handled.

FUEL AIR
ASH
 FIXED FLUIDIZED PNEUMATIC
BED BED TRANSPORT
PRESSURE
DROP

GAS FLOW/VELOCITY
 FBC Boilers

AFBC PFBC CFBC

• FURNACE and PRIMARY LOOP (FURNACE & FBHE)

• CYCLONE SEPARATOR

• CONVECTIVE BACKPASS

• AIR PRE-HEATER
• FUEL FEEDING SYSTEM

• BED MATERIAL FEEDING SYSTEM

• AIR/GAS SYSTEM

• ASH REMOVAL SYSTEM

• START-UP SYSTEM

• LIMESTONE FEEDING SYSTEM

• ASH COOLING SYSTEM

• STEAM WATER CIRCUIT

• AUTOMATIC CONTROLS
• Wide range of fuel adaptability
• Low pollution
• High combustion efficiency
• Space saving and high maintenance ability
• Capacity of boiler is large to medium

• Sulphur emission and NOx control is important

• The boiler is required to fire low-grade fuel or fuel

with highly fluctuating fuel quality.
• High Efficiency: FBC boilers can burn fuel with a
combustion efficiency of over 95% irrespective of ash
content. FBC boilers can operate with overall
efficiency of 84% (plus or minus 2%).

• Reduction in Boiler Size: High heat transfer rate over

a small heat transfer area immersed in the bed result
in overall size reduction of the boiler.
• Fuel Flexibility: FBC boilers can be operated
efficiently with a variety of fuels. Even fuels like mill
rejects, agro waste can be burnt efficiently. These
can be fed either independently or in combination
with coal into the same furnace.

• Pollution Control: SO2 formation can be greatly

minimised by addition of limestone or dolomite for
high sulphur coals. 3% limestone is required for every
1% sulphur in the coal feed. Low combustion
temperature eliminates NOx formation.
• Low Corrosion and Erosion: The corrosion and
erosion effects are less due to lower combustion
temperature, softness of ash and low particle
velocity (of the order of 1 m/sec).
• Sulphur in fuel captured in combustor by addition
of limestone

• Ca/S Molar Ratio varies between 1.5 to 2.5

depending on the Limestone Quality

• Expensive (FGD) add-on equipment avoided.

Reliability improved
• Straightforward method - Limestone addition along
with fuel into combustor

• Reactions

S + O2 SO2

CaCO3 CaO + CO2 (Calcination)

CaO + SO2 + 1/2 O2 CaSO4 (Sulphation)

 2. 5
LIMESTONE REQUIREMENT

2
Limestone Requirement

1. 5

0. 5

650 750 850 950

TEMPERATURE, DEG-C
Temperature
• NOx formation

 Thermal NOx - Nitrogen in Air

 Fuel NOx - Nitrogen in Fuel

• Thermal NOx depends on Combustion temperature

In FBC boilers, the Combustion temperature is around 850°C, hence

Thermal NOx is negligible

• Fuel NOx depends on excess air levels & Staging

In addition to low excess air levels, the combustion air is staged.

Hence Fuel NOx is also low
High Ash Neyveli Gujarat Lignite Rajasthan Washery
coal Lignite Lignite Rejects

Kiln Char Municipal Solid Petcoke Mill Rejects

Waste

Rice Husk Rice Straw Wood Palm Shells

Chips
Parameter Unit

Unit Rating MW 125

Type of Circulation Natural

SH/RH Flow t/h 405 / 336

SH/RH Pressure kg/cm2 132 / 34
SH/RH Temperature Deg C 540 / 540
FW Temperature Deg C 237
LIGNITE SPECIFICATION FOR RVUNL- GIRAL

Proximate Analysis Ultimate Analysis

Carbon % 30.09
Fixed Carbon % 19
Hydrogen % 2.24
Volatile Matter % 20
Moisture % 40 Oxygen % 6.27
Ash % 15 Nitrogen % 0.40
Sulphur % 6
Sulphur % 6
HHV kcal/kg 3000 Moisture % 40

Ash % 15
PLANT / COUNTRY FLOW PRESS. TEMP-C FUEL STARTUP MWe
T/H BAR SH/RH

STADWERKE, FRG 270 145 535/535 coal 1985 100

TEXAS, USA 499 138 540/540 lignite 1980 175
BEWAG, FRG 326 196 540/540 coal 1989 98.5
SODELIF, FRA 367 134 545/540 coal 1990 125
TEXAS , USA 499 138 540/540 lignite 1991 175
GARDANNE , FRA 700 169 565/565 lig,coal 1995 250
SLPP, INDIA 2x390 131 540/540 lignite 1999 125
VOJANY, SLOVAK 2X325 146 540/540 SA,C 1999 120
SABINAS, MEXICO 684 129 545 C res 2000 -
RED HILLS USA 2x717 173 568/540 lignite 2000 220
Starobeshevo UKRN 670 134 545/542 culm 2003 200
• Limestone size finer: The fines content ( <160µm) in
Limestone is over 90% ( now it is about 55-65%) as against
required 50% causing excess carryover and deposition in back-
pass. Inadequate ash evacuation of fly-ash from Eco hoppers
causes heavy ash accumulation in the back-pass and
overloading of ID fans. The limestone mill capacity has
reduced from 55t/h to 20t/h after the modifications to
achieve close to design requirements. Lime feeding with one
stream out of service is therefore critical to raise the load
beyond 100Mwe

• Back pass fouling: Ash accumulation

• Ash handling system Capacity: The fly-ash evacuation system
is yet to be fully established as accumulation of ash in the
hoppers is observed even at part loads. The evacuation from
intermediate bed ash bin is also not effective and affecting
the removal of bed ash from the Combustor as required.
These issues have to be resolved for taking up full load
operation of the plant.

• Lignite bunker capacity: The total capacity of the lignite

bunkers is only for 4 hrs of operation at full load. The fuel
handling plant has to be operated on a near continuous basis
for continuous operation of the boiler at full load
1. In FBC boilers fluidization depends largely on ---------
a) Particle size
b) Air velocity
c) Both (a) and (b)
d) Neither (a) nor (b)

2. The bed temperature for a FBC boiler ranges between---

a) 750 – 800°C
b) 840 – 950 °C
c) 950 - 1000°C
d) 1000 - 1200°C
3. The material used to control SO2 and NOx in the FBC boiler is
a) Limestone
b) Alumina
c) Silica
d) All of the above

4. The coal particle size used for CFBC boiler is in the range of:
a) 5 – 6 mm
b) 6 – 12 mm
c) 12 – 15 mm
d) 15 – 25 mm
5. When the boiler bed temp. exceeds beyond 950°C, the result is:
a) Low steam temperature
b) Clinker formation
c) Melting of lime stones
d) Ash carry over

6. In FBC boiler the combustion is carried out at a temperature

a) Closer to steam temperature
b) At adiabatic combustion temperature
c) At and above ash fusion temperature
d) Below ash fusion temperature of fuel used
7. Residence time of combustion particles in FBC boiler is many
times greater than conventional grate firing.
– True or False

8. Fluidized bed combustion boilers can operate with overall

efficiency of -------
a) 75 ± 2%
b) 80 ± 2%
c) 84 ± 2%
d) 90 ± 2%