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END USER : SIMHAPURI ENERGY PVT LTD

EPC BY : MADHUCON PROJECTS LTD

SUPPLIER : GREENESOL POWER SYSTEM

PVT LTD
MANUFACTURER : WUXI HUAGUANG BOILERS
LTD PR China
 Coal Combustion -Methods

• Traveling Grate (Stoker fired)

• Pulverized coal fired
• Atmospheric fluidized bed combustion
• Circulating fluidized bed combustion
• Pressurized FBC
• Coal gasification (HRSG)
 Travel grate

Slow combustion
More un burnt in combusting coal
Spreader stoker front or rear discharge
Old technology suitable for most of the solid fuels
PC
Furnace T°

• Hi thermal h
• Proven tech
• Very high
capacities
e.g. utilities
• Low Nox capture
with spl burners
• Sox capture not
viable
• Fuel flexibility poor
 FBC

• Fluidized beds suspend solid

fuels on upward-blowing jets
of air during the combustion
process.
• More effective chemical
reactions and heat transfer.
• Sox capture possible
• Suitable for coal and biomass
& other fuels.
CFBC -ADVANTAGES

• Fuel flexibility
• Low grade fuel firing
• Low Nox
• Sox capture
• High thermal h
• No clinker
CFBC Different types
CFBC different types
 OUR BOILER DETAILS
 Main Steam pressure : 13.7 Mpa

 Main Steam temperature : 540 °C

 Steaming capacity : 487 tph

 Re heater pressure in/out : 2.71 /2.57 Mpa

 Re heater temp in/out : 327 / 540 °C

 Reheating steam quantity : 419 tph

 Steam temp control range : 60-100%

 Feed water temp to eco : 250 °C

 Thermal efficiency (Imp coal) : ~ 86%

 PARTS OF BOILER
 Drum  Ash coolers
 Furnace  ID Fans
 Cyclone  PA / SA Fans
 Loop Seal  Coal Feeders
 HRA  Hot air generators
 Re heater  Over Bed Burners
 Super heaters  J seal Fan
 Economizer  Bubble Caps
 APH  Bunker
 ESP  Soot blower
 Refractory
Arrangement OF BOILER & ESP
PLAN VIEW OF BOILER & ESP
STEAM DRUM
 Furnace
Flue
-Top supported
-Membrane walled -Metal spray:
-Wing walls -Important measurements

for water panels Temperature

for super heaters Inventory

-Refractory lining Draining of bed

-SA injection Solids circulation

-PA from Bottom

SA -Section area: Upper
SA
Lower

PA
 The furnace design
– higher bed velocity : 5.2 - 5.5m/s
– Lower top velocity : 4.4 - 4.6 - 5.2 m/s
 The furnace height
– Extend residing time
– Once through 6.8 - 7s
 Advantages
– Low abrasion
– High reliability
– High combustion efficiency
 Control bed temperature for variety of heat fuel
 Control furnace outlet temperature to prevent super heater erosion
 Keep main steam parameters at 50%MRC
 Low Nox emission at different load
BUBBLE CAPS
 CIRCULATION
Circulation ratio 25-30
Separation Rate 99.5 %
 Flue

CYCLONE
Membrane walled
Steam as media
Velocity of recycling
20-25 m/s
Escape particle size 60 m
Refractory lining

High separation efficiency

Ash Highly reliable

Keep lower recirculation
ash temperature
Low melting point: 1020C
 LOOP SEAL
 Balancing the solids

 Recirculation

 Controlling Furnace t °

 Back sifting

 Front seal air qty via rear

 Erosion

Seal air Seal air  Free downward expansion

 Refractory critical
 J SEAL Fan

Roots Blowers
2 working 1 Standby
Capacity:4800 Nm3/hr
Pressure:67500 Pa
 Refractory
• Plastic refractory
• Abrasion resistant refractory
• Monolithic
Refractory Interface
 HRA
Second pass
Cyclone out MOC: SA 210 A1
Membrane walled
Steam as media
Top supported
Enclosure for super
heaters,
Re heaters
Cyclone
Re heater
Operating pr: 2.71 Mpa

Steam flow

Steam t °C I/t:327 °C

Steam t °C o/t:540 °C

Controls by Dampers

Emergency by spray

MOC SA 210 A1
Super heaters
LT super heater

Steam t° in /out:

Flue gas t° in / out

HT super heater

Steam t° in /out:

Flue gas t° in / out

Controls by Dampers/ spray

MOC T11, T22, T91

Control Damper
Flue in

Four Dampers –
2 nos in Re heater & 2 in super heater
Temperature control esp. during start up
Isolation of Re heater when required
Economizer
Water t° C in : 250

Water t° C out :

Flue in t° :

Flue out t° :

MOC: SA210 A1
 APH
TUBULAR Three pass

Air in tube

Flue outside

Air in t°C : 250

Air out t°C :

Flue in t° :

Flue out t° :

MOC: CS /carton steel

ESP

Inlet gas Q:

Inlet j :

Outlet j: 50 mg/Nm3

(All fields in operation)

 COAL FEEDERS

Capacity:
N-1 condition: 6 working normal; 5 to meet MCR
VFD driven
COAL FEEDING
 ASH COOLERS
ASH
CW

4 coolers working
N-1 condition
3 to meet MCR
Ash treated:
Ash in t° C< 950
Ash out t° C <150
Particle size:
CW ASH
< 12 mm (typ)
Start up / Load Burners
 Hot air generators

No of burners: 4 Capacity : 1000 lpm Fuel: LDO /HSD

Ignition : HEA (Retracting)
Max WP 25 kg/cm2 Min WP: 10 kg/cm2
Atomizing: Pressure jet
 Over Bed Burners

No of burners: 4 Capacity : 1200 lpm Fuel: LDO /HSD

Ignition : HEA (Retracting)
Max WP : 25 kg/cm2 Min WP: 10 kg/cm2
Atomizing: Pressure jet
 ID Fans

ID Fans : 2 x 60%
Fan Flow : Nm3/hr
Head MCR : mm wc
Margins H/Q :
Speed control by fluid coupling
 PA / SA Fans

PA 2 x 60% SA 2 x 60%

Fan Flow Nm3/hr Fan Flow Nm3/hr

Head mm wc Head MCR mm wc

Margins H/Q = Margins H/Q =

Speed control by fluid coupling Speed control by fluid coupling
 Deaerator

Capacity -De aeration: 530 tph Storage: 10 min MCR

Feed water inlet temp :
Feed water outlet temp : 160 deg C
 Coal sieve
燃煤粒度分布 Coal Analysis

100
筛下物重量百分比 % passing

10

燃煤粒度分布

1
0.01 0.10 1.00 10.00 100.00
mm
 Sieve analysis- Coal
Average size Cum passing
>10 mm 11.402 100.00
10-8 mm 8.944 95.00
8-5.6 mm 6.693 86.00
5.6-4 mm 4.733 82.00
4-2.8 mm 3.347 68.20
2.8-2 mm 2.366 58.20
2-1.4 mm 1.673 42.60
1.4-1.0 mm 1.183 36.50
1.0-0.71 mm 0.843 32.00
0.71-0.5 mm 0.596 28.00
0.5-0.355 mm 0.421 22.20
0.355-0.25 mm 0.298 20.30
0.25-0.18 mm 0.212 16.50
0.18-0.125 mm 0.150 12.10
0.125-0.09 mm 0.106 8.30
0.09-0.063 mm 0.075 5.20
<0.063 mm 0.045 1.86
 Coal analyses
Design Min Max
Proximate Analysis (ARB) Imp coal Ind coal Imp coal Ind coal Imp coal Ind coal
Moisture % 26 10.5 23 35 16.5
Volatile Matter % 34.52 21 33 36 19.5
Fixed Carbon %Ash % 32.38 26.2 31 34 20
Ash % 6 42.3 3.5 7 44
Sulphur (A.D. Basis)
Organic % 0.82 0.7 0.95
Pyretic % 0.09 0.03 0.15
Sulphate % 0.09 0.03 0.2
GCV 4800 3280 4600 5200 2900
Ultimate Analysis
Carbon % 74.28 33.73 70.9 76.5 30.9
Hydrogen % 4.59 2.35 3.5 6.5 2.09
Nitrogen % 1.5 0.75 1.35 1.71 0.85
Oxygen % 18.62 5.48 16.3 22 5
Sulpher % 1.01 0.37 0.99 1.68 0.36
 Lime stone / Bed material
石灰石粒度分布 Lime stone /Bed material

100
筛下物重量百分比 % passing

10

石灰石粒度分布
1

0
0.01 0.10 1.00 10.00
mm
 Lime stone sieve sizes
2-1.4 mm 1.673 100.00

1.4-1.0 mm 1.183 99.00

1.0-0.71 mm 0.843 96.00

0.71-0.5 mm 0.596 84.84

0.5-0.355 mm 0.421 67.49

0.355-0.25 mm 0.298 46.90

0.25-0.18 mm 0.212 24.97

0.18-0.125 mm 0.150 10.90

0.125-0.09 mm 0.106 4.50

0.09-0.063 mm 0.075 1.36

<0.063 mm 0.045 0.47

Density / Temp profile
Temperature profiles

Ttop

Tseal-pot

Tbottom
 Nox & Sox capture in CFB
• Nox produced in combustion (Thermal Nox)

• Nox in fuel released (Fuel Nox)

• Low Nox when combustion is done below 1650 deg F or 899 deg C

• Staged combustion reduces Nox

• Lime stone injection Sox capture

• Typical Ca to S molar ratio 1.8 to 2.5 (depending on Sulpur content

of fuel and reactivity of lime)

• If combustion temp is < 800 or > 900 deg C Sulfur capture is low.
Lime stone consumption
 Controls on CFBC
• Furnace pressure
• PA SA pressure
• Wind Box pressure ( Monitoring)
• Furnace bottom pressure
• Furnace DP
• PA SA split flow
• Fuel flow
• Bed temperature control
• Bed level control
• Steam drum level control
• Steam temperature control – Damper / Spray water
• Re heater steam temperature control
• J seal air flow ( less critical )
Start up curves
Hot start up
 CFBC Heat transfer
• Combustion in sub-stoichiometric condition
• Concentrates CO and C and limits availability of O2
• Staged combustion ( 60% PA and 40% SA)
• Constant temperature profile
• Solids to transfer heat ; Particle size critical
• Bulk density of inventory materials critical -Greater bulk density
greater heat transfer
• Recycle controls bulk density
• Upper furnace bulk density increases furnace exit gas temp
decreases
• Upper furnace temperature high then increasing PA increases bulk
density and heat transfer
• Increase of PA dilutes lower bed density
• Make up materials required depends on how fuel contributes inventory
and how well is its integrity
• Particle temperature critical
• Air split changes furnace temperature profile
• EA is contributed by SA & hence O2 trim is by SA
• Ash drain changes density
• Particle density different at furnace bottom to top
• Ash split is 70% thro fly ash and 30% by bed ash
 Interlocks
• J seal fans trip ID Fans trip

• ID trip PA trip SA trip

• Furnace pressure very low ID trip

• Furnace pressure very high PA trip

• Bed temp low PA trip

• Bed level low Ash cooler stop

• Bed temp high Burners trip

Coal feeders trip

• Drum level very low ID trip

 Control logics Brief
• Furnace pressure By ID fan ( VSC / Dampers)

• Total air By PA + SA (VSC / Dampers)

• O2 By SA

• Steam pressure By coal feeders (VFD) + fans

• Bed level Ash coolers (VFD)

• Bed inventory Coal + bed materials + limestone

• Bed temperature Coal feeders (VFD)

• Steam temp Attemperator / dampers cascade

Thank you !