Boiler Operation Manual

2 Design and Performance Data

Employer: Yumn Ltd
Supplier: Shapoorji Pallonji & Co. Pvt. Ltd
Project No.: C-02-824924-088
Document No.: C02824924088_0003001_0024194 Date issued: 22.02.2019
Customer Doc. No. : 00-00-0000

Rev. Date/Author Date/Checked Date/Approved Status of the document

0A 19.02.2019 / Amh 19.02.2019 / HPi 19.02.2019 / Mauri Preliminary

Heinonen

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Table of contents

2 Design and Performance data ................................................................................................................ 4

2.1 Site Conditions ................................................................................................................................. 4
2.2 Boiler Capacity ................................................................................................................................. 4
2.3 Main Steam Pressure....................................................................................................................... 5
2.4 Main Steam Temperature ................................................................................................................ 5
2.5 Feed water ....................................................................................................................................... 5
2.6 Fuels ................................................................................................................................................ 5
2.6.1 Peat elementary analysis ................................................................................................ 6
Ash chemical composition: .............................................................................................................. 7
2.6.2 Dimensioning points ........................................................................................................ 8
2.6.3 Particle size of peat ......................................................................................................... 9
2.6.4 Auxiliary fuel .................................................................................................................. 10
2.7 Structure, materials and dimensioning........................................................................................... 10
2.7.1 Pressure parts definitions .............................................................................................. 10
2.7.2 Design pressure............................................................................................................. 11
2.7.3 Feed water system ........................................................................................................ 11
2.7.4 Boiler water and steam cycle......................................................................................... 12
2.7.5 Boiler valves .................................................................................................................. 15
2.7.6 Silencer for Safety Valves ............................................................................................. 16
2.7.7 Blow down, venting and draining ................................................................................... 16
2.7.8 Sootblowing ................................................................................................................... 16
2.8 Feed Water Quality ........................................................................................................................ 17
2.9 Boiler Water Quality ....................................................................................................................... 17
2.10 Bed Material ................................................................................................................................... 18
2.11 Quick Lime ..................................................................................................................................... 18
2.12 Instrument Air and Compressed Air ............................................................................................... 19
2.13 Cooling Water ................................................................................................................................ 19
2.14 Service Water................................................................................................................................. 20
2.15 Effluent Treated Water ................................................................................................................... 20
2.16 Demineralized Water...................................................................................................................... 21
2.17 Predicted performance ................................................................................................................... 22
2.17.1 Boiler fuel ....................................................................................................................... 22
2.17.2 Boiler main parameter ................................................................................................... 23
2.17.3 Steam parameters ......................................................................................................... 24
2.17.4 Flue gas parameters ...................................................................................................... 27
2.17.5 Combustion air parameters ........................................................................................... 29
2.17.6 Informative consumption data ....................................................................................... 31

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 2.17.7 Firing diagram ................................................................................................................ 32

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2 Design and Performance data

In this chapter is collected essential design and performance information of power boiler.

2.1 Site Conditions

Site location in Southern Rwanda

alongside the Akanuyaru
river and the border with
Burundi; at Buye village,
Kabumbwe cell, Mamba
sector, Gisagara District in
souther province of
Rwanda.
Elevation above the sea level m 1400
Ambient temperature
• Maximum / minimum °C 32 / 7

• Design temperature °C 26

Ambient pressure mbar(a) 860

Ambient air relative humidity
• Maximum / minimum relative humidity % 99 / 30

• Relative humidity at 26°C temperature % 70

Ambient relative moisture g w /kg dry 17,5

2
Seismic load defined as per EN 1998 – 1 : 2010 and British m/s 1,6
Naional Annexure. General requirements in accordance to
Rwanda Building Code, Chapter 2, section 6:
Peak ground acceleration

2.2 Boiler Capacity

100 % maximum continuous rating (MCR) with guarantee fuel kg/s 42,4
(E-100TMCR)
t/h 152,5
103 % load (E-103BMCR) kg/s 43,6
t/h 157,1
Minimum load, 40 % of MCR with design fuel mixture kg/s 16,9
t/h 60,8

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2.3 Main Steam Pressure

Main steam pressure at boiler outlet bar(g) 82

2.4 Main Steam Temperature

Main steam temperature at boiler outlet at MCR load °C 525

Main steam temperature control range with design fuel mixture % 70-100
firing

2.5 Feed water

Boiler load % MCR 100

Feed water temperature before boiler °C 190

2.6 Fuels

The main fuel is peat. The peat quality has large variations depending on harvesting area and depth. The
peat is sun-dried in the long term storage area and then transported to the fuel yard at the site.

Peat chemical analysis ranges:

Average
Fuels Unit Range
fuel

NCV, dry ash free MJ/kg 20,8 17-23,8

NCV, dry (calc.) MJ/kg 16,8 13,7-19,2 @19,4% ash
Moisture, H 2 O %-w(wb) 40 35-50
NCV, as received MJ/kg 9,1 7,2-10,5 @40%
(calc.) moisture,
19,4% ash
Ash in dry fuel %-w(db) 19,4 10-35
Sulphur in dry fuel %-w(db) 1,1 0,4-1,4
Nitrogen in dry fuel %-w(db) 1,6 < 2,0
Chlorine in dry fuel %-w(db) 0,03 0,004-0,06
Sodium + potassium in %-w(db) 0,21 < 0,56
dry fuel
Lead in dry fuel mg/kg 15 < 30
3
Specific weight (bulk) kg/m 250 200-350 @42% H2O,
10-35% ash

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2.6.1 Peat elementary analysis

Elementary analysis:

Average
Fuels Unit Fuel F
fuel

Ash content (550°C) %-w(db) 19,4 30

Sulphur content %-w(db) 1,1 0,8
Volatile matter %-w(db) 57,3 68,61
Oxygen (calc.) %-w(db) 27,7 23,84
Cross calorific value MJ/kg, dry 17,8
Net calorific value MJ/kg, dry 16,8 13,7
Net calorific value MWh/t, dry 4,66 3,81
(calc.)
Carbon C %-w(db) 45,5 40,31
Hydrogen H %-w(db) 4,7 3,82
Nitrogen N %-w(db) 1,6 1,21

Ash fusibility characteristics:

Minimum Average
values values

Fusibility of ash Shrinkage temp, °C 840 1195

(ox. atm.), ST
CEN/TS 15370 Deformation °C 1160 1310
temp, DT
Hemisphere °C 1180 1350
temp, HT
Flow temp, FT °C 1210 1370
Fusibility of ash Shrinkage temp, °C 780 1110
(red. atm.), ST
CEN/TS 15370 Deformation °C 1030 1225
temp, DT
Hemisphere °C 1120 1275
temp, HT
Flow temp, FT °C 1140 1300

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Ash chemical composition:

Average Average
Unit
fuel values

Results of the Sodium, Na %-w(db) 0,08

semi quantitative Magnesium, Mg %-w(db) 0,29
X-ray analysis as Aluminium, AI %-w(db) 2,69
elements Silicon, Si %-w(db) 3,90
Phosphorous, P %-w(db) 0,05
Sulphur, S %-w(db) 1,35
Chlorine, Cl %-w(db) 0,04
Potassium, K %-w(db) 0,20
Calcium, Ca %-w(db) 1,54
Titanium, Ti %-w(db) 0,11
Vanadium, V %-w(db) 0,01
Chromium, Cr %-w(db) 0,01
Manganese, Mn %-w(db) 0,05
Iron, Fe %-w(db) 1,74
Zinc, Zn %-w(db) 0,01
Lead, Pb %-w(db) 15*
Rubidium, Rb %-w(db) 0,01
Strontium, Sr %-w(db) 0,01
Zirconium, Zr %-w(db) 0,01
Barium, Sa %-w(db) 0,03
Note *: Pb analysis by Labtium Oy, 30.4.2014

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Average values of ash components as oxides (source: SWECO analysis)

Average
Unit Average fuel
values

Sodium, Na 2 O %-w (ash basis) 0,48

Magnesium, MgO %-w (ash basis) 1,99
Aluminium, AI 2 O 3 %-w (ash basis) 19,33
Silicon, SiO 2 %-w (ash basis) 42,17
Phosphorous, P 2 O 5 %-w (ash basis) 0,53
Sulphur, SO 3 %-w (ash basis) 8,74
Barium, BaO %-w (ash basis) 0,14
Potassium, K 2 O %-w (ash basis) 1,22
Calcium, CaO %-w (ash basis) 8,39
Vanadium, V 2 O 5 %-w (ash basis) 0,02
Chromium, Cr 2 O 3 %-w (ash basis) 0,01
Rubidium, Rb %-w (ash basis) 0,01
Strontium, SrO %-w (ash basis) 0,01
Zirconium, ZrO 2 %-w (ash basis) 0,01
Chlorine, Cl %-w (ash basis) 0,04
Note: The element analysis and the oxide analysis do not match fully because they are based om different
analyzing campaigns. The intention is to give a picture about the average values of ash components.

2.6.2 Dimensioning points

F / Worst
Main fuel B D E
fuel

NCV, dry ash free MJ/kg 20,8 20,8 20,8 17

NCV, dry (calc.) MJ/kg 16,8 16,8 16,8 13,7
Moisture, H 2 O %-w(wb) 35 40 45 50
NCV, as received MJ/kg 10,0 9,1 8,1 5,6
(calc.)
Ash in dry fuel %-w(db) 19,4 19,4 19,4 30
Sulphur in dry fuel %-w(db) 1,1 1,1 1,1 0,8
Chlorine in dry fuel %-w(db) 0,03 0,03 0,03 0,03
3
Specific weight (bulk) kg/m 230 250 270 300

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2.6.3 Particle size of peat

Fuel particle size (P) before it is fed to the boiler must be according to class P63 CEN/TS 14961-1:

3.15 mm < P < 63 mm > 75 % of weight

P < 3.15 mm < 25 % of weight

Additionally fuel particle length must fulfill the following requirement:

> 100 mm < 10 % of weight

< 350 mm 100 % of weight

Fuel shall be essentially free of impurities such as stones, metals, glass and other inert objects. Especially
large size impurities should be removed before the boiler.
Impurities in fuel must stay below following limits (particle size = largest dimension):
• Sand (particle size < 2 mm) is allowed together with fuel ash up to max ash content as specified in
"Variation of fuel properties". Sand softening point must be above 1100°C.

• Impurities with particle size greater than 2 mm and smaller than 15 mm: max 0.05 % of dry fuel
mass flow

• Impurities with particle size greater than 15 mm: max 0.01% of dry fuel mass flow

• Impurities larger than 50 mm (within max. fuel particle size limitation): sporadic and occasional
objects are allowed but they may disturb boiler operation.

• Max total inorganic non-combustible material (ash+sand+impurities) up to max ash content as

specified in "Variation of fuel properties"

The impurities in fuel will increase bed material consumption. By using bottom ash recycling system the bed
material consumption can be mitigated. Damages and unavailability caused by impurities larger than 50 mm
are excluded from warranties.

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2.6.4 Auxiliary fuel

Light fuel oil is used for start-up. Example of South-African quality.

Heating value (LHV) MJ/kg 42

3
Density kg/m (20 °C) 800
Sulphur ppm 50 (low suplhur)
500 (standard)
2
Viscosity mm /s (40 °C) 2,2-5,5
Flash point °C 55

Cold filter plugging point °C -4

Carbon residue wt-% less than 0,2

Water vol-% 0,05

Ash w-% 0,01

2.7 Structure, materials and dimensioning

2.7.1 Pressure parts definitions

The pressure parts of the Power Boiler are designed, manufactured and inspected according to the ASME,
Boiler and Pressure Vessel Code, without stamp.
Section I, Latest Edition (Power Boilers).

The boiler proper, boiler external piping and non-boiler external piping are designed, fabricated, assembled
and inspected in accordance with the following laws and regulations with edition, which was valid at the time
of signing the contract, with the following exceptions:

a) The Certificate of Authorization (ASME) not required

b) The ASME Certification Mark not stamped
c) Data Report Forms not issued
d) Drawings and strength calculations not stamped

Applicable codes and standards were followed:

ASME BOILER AND PRESSURE VESSEL CODE (BPVC)
Sections
I Rules for Construction of Power Boilers
II Materials
V Nondestructive Examination

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VIII Rules for Construction of Pressure Vessels; Div. 1
IX Welding and Brazing Qualifications

External piping according to power piping code ASME B31.1.

2.7.2 Design pressure

The boiler design pressures and set pressures for safety valves are as follows:

Boiler design pressure bar(g) 102

Economizer calculation pressure bar(g) 104
Superheater pressure drop – predicted bar 8
Operating pressure at MCR

In drum predicted bar(g) 90

After superheater main valve bar(g) 82
Preliminary safety valve settings

Superheater line SV (25%MCR)

Set pressure bar(g) 90

Fully open bar(g) 93
Reset at bar(g) 85
Drum SV (75%MCR)

Set pressure bar(g) 102

Fully open bar(g) 105
Reset at bar(g) 96

2.7.3 Feed water system

2.7.3.1 Feed water piping

Feed water pipe from valve to economizer

Number of connecting pipes pcs 1

Tube size mm 168,3

Tube material - SA106B

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Feed water pipe from economizer to drum

Number of connecting pipes pcs 1

Tube size mm 168,3

Tube material - SA106B

2.7.4 Boiler water and steam cycle

2.7.4.1 Fluidizing grid

The Andritz bubbling fluidized bed is water cooled nozzle bottom fluidizing grid which is specially designed
for effective coarse material removal from the bed. Fluidizing nozzles are installed between the evaporator
tubes forming the boiler bottom.
The nozzle bottom is equipped with ash funnels and chutes to remove coarse material from bed. Primary air
(fluidizing air) is conveyed to the wind box below the nozzle bottom and from there via nozzles to fluidizing
bed.
Air box below nozzle bottom is divided in parts two to accommodate partial fluidization at low loads.

Fluidizing grid width mm 8 360

Fluidizing grid depth mm 6 864
2
Fluidizing grid area m 54,9
2
Fluidizing grid heat release kW/m 2 200
Number of nozzles pcs 1702
Nozzle spacing mm*mm 180x176
Nozzle material - AISI304L

Cooling tube size mm 63,5x5,08

Cooling tube material - SA192
Cooling tube pitch mm 176
Refractory height from boiler bottom mm 3 000
Refractory thickness at walls (from tube surface) mm 50
2
Refractory area m 91

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2.7.4.2 Furnace walls and roof

Furnace walls are of welded gas-tight membrane construction. The furnace roof is a continuation of the front
wall of the furnace.

Furnace
Furnace width mm 8 360
Furnace depth mm 6 864
Furnace height from nozzle bottom to screen top m 27,8
Wall tube size mm 63,5x5,08
Tube material - SA192
Tube transverse pitch mm 88
Fin width mm 24,5
Fin thickness mm 6
Fin material - 16Mo3
2
Furnace cooled wall area m 842

Material of headers SA106B

Distribution header size mm 273 / 219,1
Collector header size mm 219,1
Furnace equipment
- Secondary air nozzles pcs 8
- Tertiary air nozzles pcs 8
- Start-up burners pcs 2
- Fuel feeding chutes pcs 4
- Sight glasses pcs 7
- Opening for sand feed pcs 1
- Openings for the maintenance platform (on the walls) pcs 4
- Service openings, ∅800 mm pcs 1
- Service openings, 400x600 mm pcs 5
- Service openings ∅600 mm pcs 1
- Ash removal chutes pcs 6

The furnace is designed to withstand a ±5 kPa pressure. An explosion relief corner is provided for the
purpose of easy rupture and release of furnace pressure in the event of an explosion in order to minimize
damage of the boiler pressure parts and danger to personnel.

Furnace headers are equipped with inspection nozzles.

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2.7.4.3 Furnace rear wall screen tubes

Channel width mm 8 360

Channel depth mm 4 700
Tube size mm 63,5x5,08
Tube material - SA192
Tube transverse pitch mm 264
Tube vertical pitch mm 100
Number of tubes across flue gas flow direction pcs 31
Number of tubes along flue gas flow direction pcs 3
2
Heat transfer surface area m 145
Size of headers, main mm 457

2.7.4.4 Second pass walls

Second pass walls are part of evaporation circuit. Water is taken from drum and it is returned to own part of
steam box in drum to keep it separate from main furnace strong water circulation.

Channel width mm 8 360

Channel depth mm 4 000
Height from rear wall header to front wall top mm 12
Tube size mm 63,5x5,08
Tube material - SA192
Tube transverse pitch mm 120
2
Heat transfer surface area m 309

Size of headers, RW distributing mm 406,4

Size of headers, others mm 219,1

2.7.4.5 Convective evaporator

Convective evaporator consists of one tube bank located in the second pass. Bank is located after the
superheaters. Water / steam mixture flows cross-current to the flue gas flow.

Channel width mm 8 360

Channel depth mm 4 000
Tube size mm 51x5,08
Tube material - SA192
Tube transverse pitch mm 120
Tube vertical pitch mm 100

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 Number of tubes across flue gas flow direction pcs 67
Number of tubes along flue gas flow direction pcs 6
Number of tubes connected in parallel pcs 3
2
Heat transfer surface area m 258
Number of banks pcs 1
Size of headers, main mm integrated

2.7.4.6 Downcomers, supply and upper circulation tubes

Main downcomers for furnace

Main downcomer outside diameter mm 508
Number of downcomers pcs 2
Tube material - SA106B

Upper circulation pipes

Upper circulation pipe size mm 168,3
Number of upper circulation pipes pcs 24
Tube material - SA106B

2.7.4.7 Steam piping

Superheater connection pipes

Number of connecting pipes between superheaters pcs 2
Tube size mm 323,9
Tube material - SA335P22

Live steam pipe up to main steam valve

Live steam pipe size mm 323,8 x 25,4
Tube material - SA335P91

2.7.5 Boiler valves

Boiler main valves are:

Main valves
Feed water valve group pcs 1
Live steam valve with bypass pcs 1
Start-up valve (40% MCR) pcs 1
Live steam pipe safety valves pcs 1
Sootblowing line safety valve pcs 1
Drum safety valve pcs 1
Blow down valves pcs 1

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2.7.6 Silencer for Safety Valves

The boiler is equipped with silencer for the following valves:

• Start-up valve

• Safety valve for superheated steam

• Safety valve for drum steam

• Safety valve for sootblowers

2.7.7 Blow down, venting and draining

The blow down system is designed for 3% MCR flow. Typical blow-down value is 1%.

3
Continuous blow down tank m 1,1
• material SA516 Gr.70
3
Blowdown tank m 3
• material SA516 Gr.70

2.7.8 Sootblowing

Sootblowing system comprises of sootblowers and piping needed to connect them to the pressurized steam
source. Pressurized steam for sootblowing is taken from after the primary superheater.

Sootblowing steam pressure, normal bar(g) 20

Sootblowing steam temperature, normal °C 356
Sootblowing steam pressure, design for piping bar(g) 39
Sootblowing steam temperature, design for piping °C 420

Superheaters and boiler bank are equipped with fully retractable sootblowers while economizer banks and
flue gas air preheater banks are equipped with partially retractable sootblowers.
Heat exchanger tubes located closest to sootblowers are protected with tube shields. Tube shield length is
normally 1.0 m.

Sootblowers
Fully retractable sootblowers (from 1 wall) pcs 7
Partially retractable sootblowers (from 1 wall) pcs 8

Sootblowing steam is conveyed to sootblowers via separate piping.

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Sootblower piping:
Motor-operated on/off valve pcs 1
Steam pressure control valve pcs 1
Automatic draining valves pcs 2
Sootblowing line safety valve pcs 1

2.8 Feed Water Quality

The water quality into the boiler after feed water tank shall be according to EN 12952-12 as follows:

Acid conductivity (@25°C) µS/cm < 0,2

pH(@25°C) - > 9,2
Oxygen O 2 mg/l < 0,1
Iron Fe mg/l < 0,02
Silica SiO 2 mg/l < 0,02
Copper Cu (max.) mg/l < 0,003
Sodium Na+ Potassium K (max.) mg/l < 0,01
Organic matter as KMnO4 mg/l < 5,0
Oils and greases mg/l < 0,5

2.9 Boiler Water Quality

According to EN 12952-12:

pH(@25°C) - 9.5-10.5
Direct conductivity (@25°C) µS/cm < 50
Na + K mg/l 0,05-0,3
Silica SiO 2 mg/l <2

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2.10 Bed Material

Bed material is natural, screened sand. Properties are as follows:

Property Unit Value

Na 2 O % <3
K2O % <4
H2O % < 0.3
3
Density kg/m 1300-1500
Softening point (DTA method) °C > 1 100
Share of quartz % < 35
Sand shall not contain chlorine or weak acid soluble alkalis.

Bed material particle size is as follows:

Sand shall be sieved, not crushed Unit Value

< 2 mm % 100
< 1 mm % > 90
< 0.5 mm % < 15
< 0.25 mm % <5

2.11 Quick Lime

The below analysis shall be used when designing the equipment:

Available lime (as calcium oxide CaO) wt-% > 85

Magnesium oxide (MgO) wt-% <5
Other wt-% < 10

Physical properties:
Appearance and Odour White or yellow white
powder
Specific gravity 3,0 – 3,2
3
Bulk density kg/m 980-1020
Particle size mm 0-1
Moisture % < 1,0

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Quick lime specification as precondition for CaO consumption guarantee:
Available lime (as calcium oxide CaO) wt-% > 90
Iron as Fe2O3 wt-% < 1,0
Alumina as Al2O3 wt-% < 0,5
Magnesium oxide (MgO) wt-% < 1,75
Silicon Dioxide (SiO2) wt-% < 1,5
Acid insoluble residue wt-% < 0,3
Reactivity * °C/min > 13
Loss of ignition (L.O.I) wt-% < 2,5
Sulphur as SO3 wt-% < 0,2
Soluble in water at 25 °C wt-% < 2,0
*According to ASTM C110

2.12 Instrument Air and Compressed Air

The instrument air is clean, oil free, with a dew point of -20 °C at least and is delivered at a nominal pressure
of 7,0 bar(g) after the drying devices.

2.13 Cooling Water

Cooling water is used for:

- Closed cooling water heat exchangers

Cooling water quality:

pH - 7-8, target
value 7,5
Hardness (CaCO3) mg/l < 30
Cl mg/l < 100
Sulphates (SO42) mg/l < 450
Scale inhibitor residue mg/l > 0,1
Corrosion inhibitor residue mg/l > 0,1
Biological control residue mg/l > 0,1
Temperature °C 27
Pressure (operating) bar(g) 4,62

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manuals\02_Design_and_Performance_Data.docx
2.14 Service Water

Service water is used for:

- Flue gas cleaning system hydrators
- Emergency showers
- Blow down tank cooling

Service water quality:

pH - 7-8, target
value 7,5
Hardness (CaCO3) mg/l < 30
Cl mg/l < 100
Sulphates (SO42) mg/l < 450
Scale inhibitor residue mg/l > 0,1
Corrosion inhibitor residue mg/l > 0,1
Biological control residue mg/l > 0,1
Temperature °C 27-30
Pressure (operating) bar(g) 5

2.15 Effluent Treated Water

Effluent treated water is used for:

- Flue gas cleaning system mixers

Effluent water quality:

Parameter Rwanda Standard RS

109:2009
pH - 5-9*
TSS mg/l 50
TDS mg/l 2000
Temperature increase °C ≤3
Max BOD5 (@ 20°C) mg/l 50
COD mg/l 250
Soluble reactive phosphorous mg/l 1,5*
Sulphides mg/l 1
Sulphates mg/l 400
Calcium mg/l 500
Colour and odour TCU 50

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manuals\02_Design_and_Performance_Data.docx
 Feacal coliform MPN/100 ml 400
Ammonia (as N) mg/l 20
Cyanides mg/l 0,1
Chlorides mg/l 600
Total residual chlorine mg/l 0,2*
Fluoride mg/l 1,5
Iron mg/l 1*
Manganese mg/l 0,1
Boron mg/l 0,5
Arsenic mg/l 0,01
Cadmium (Cd) mg/l 0,01
Total Chromium (Cr) mg/l 0,5*
+6
Hexavalent Chromium (Cr ) mg/l 0,05
Copper mg/l 0,5*
Lead (Pb) mg/l 0,1
Mercury (Hg) mg/l 0,0002
Nickel mg/l 2*
Selenium mg/l 0,02
Zinc mg/l 1*
Phenols mg/l 0,2
Benzene mg/l 0,1
Oil and Grease mg/l 10

2.16 Demineralized Water

Demineralized water is used in chemical system.

Water treatment plant, demi-water quality:

Cation exchanged conductivity (25°C) µS/cm 0,2
pH -l 6,5-7,5
Total hardness mmol/l < 0,0005
Sodium + Potassium mg/l < 0,010
Iron mg/l < 0,020
Copper mg/l < 0,003
Silica mg/l < 0,020
Organic matter as KMnO4 mg/l < 5,0
Oils and greases mg/l < 0,5

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manuals\02_Design_and_Performance_Data.docx
2.17 Predicted performance

2.17.1 Boiler fuel

Case E_103BMCR E_100TMCR E_70TMCR E_40TMCR F_65TMCR F_40TMCR

BOILER FUEL Load 100 % 97 % 69 % 39 % 64 % 40 %
Carbon C %-w(db) 45.50 45.50 45.50 45.50 40.31 40.31
Hydrogen H2 %-w(db) 4.70 4.70 4.70 4.70 3.82 3.82
Nitrogen N2 %-w(db) 1.60 1.60 1.60 1.60 1.21 1.21
Chlorine Cl %-w(db) 0.03 0.03 0.03 0.03 0.03 0.03
Sulphur S2 %-w(db) 1.10 1.10 1.10 1.10 0.80 0.80
Oxygen O2 %-w(db) 27.67 27.67 27.67 27.67 23.83 23.83
Ash %-w(db) 19.40 19.40 19.40 19.40 30.00 30.00
Moisture H 2O %-w(wb) 45.00 45.00 45.00 45.00 50.00 50.00
Dry fuel heating value, LHV kJ/kg 16 800 16 800 16 800 16 800 13 700 13 700
Dry fuel heating value, HHV kJ/kg 17 826 17 826 17 826 17 826 14 534 14 534
LHV, as received kJ/kg 8 141 8 141 8 141 8 141 5 629 5 629
HHV, as received kJ/kg 9 804 9 804 9 804 9 804 7 267 7 267
Total ash flow from the boiler t/d 144 140 100 56 193 120

Case D_103BMCR D_100TMCR D_70TMCR D_40TMCR

BOILER FUEL Load 100 % 97 % 69 % 39 %
Carbon C %-w(db) 45.50 45.50 45.50 45.50
Hydrogen H2 %-w(db) 4.70 4.70 4.70 4.70
Nitrogen N2 %-w(db) 1.60 1.60 1.60 1.60
Chlorine Cl %-w(db) 0.03 0.03 0.03 0.03
Sulphur S2 %-w(db) 1.10 1.10 1.10 1.10
Oxygen O2 %-w(db) 27.67 27.67 27.67 27.67
Ash %-w(db) 19.40 19.40 19.40 19.40
Moisture H 2O %-w(wb) 40.00 40.00 40.00 40.00
Dry fuel heating value, LHV kJ/kg 16 800 16 800 16 800 16 800
Dry fuel heating value, HHV kJ/kg 17 826 17 826 17 826 17 826
LHV, as received kJ/kg 9 103 9 103 9 103 9 103
HHV, as received kJ/kg 10 695 10 695 10 695 10 695
Total ash flow from the boiler t/d 139 136 95 54

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2.17.2 Boiler main parameter

Case E_103BMCR E_100TMCR E_70TMCR E_40TMCR F_65TMCR F_40TMCR

BOILER MAIN PARAMETERS Load 100 % 97 % 69 % 39 % 64 % 40 %
Boiler fuel power (LHV), EN kJ/s 127 024 123 645 86 525 49 027 84 086 51 683
Calculated effic. acc. EN12952-15 % 88.64 88.68 88.24 87.99 85.82 84.71
Boiler fuel mass flow (EN12952-15) kg/s 15.6 15.2 10.6 6.0 14.9 9.2
t/d 1 348 1 312 918 520 1 291 793
Boiler fuel power (HHV), ASME kJ/s 153 612 149 526 104 609 59 263 109 428 67 218
Calculated effic. acc. ASME PTC4 % 74.95 74.98 76.07 76.21 67.66 68.68
Boiler fuel mass flow (ASME PTC4) kg/s 15.7 15.3 10.7 6.0 15.1 9.3
t/d 1 354 1 318 922 522 1 301 799
Boiler steam power kJ/s 115 134 112 118 79 579 45 165 74 043 46 166
Live steam mass flow kg/s 43.6 42.37 29.3 16.9 27.10 16.9
t/h 157.0 152.5 105.5 60.8 97.6 60.8
Live steam temperature °C 525.0 525.0 525.0 472.5 525.0 496.0
Live steam pressure bara 83.0 83.0 83.0 83.0 83.0 83.0
Feed water temperature °C 191.4 190.0 174.1 153.9 170.4 153.9
Feed water pressure bara 96.0 95.5 90.7 87.3 89.9 87.3

Case D_103BMCR D_100TMCR D_70TMCR D_40TMCR

BOILER MAIN PARAMETERS Load 100 % 97 % 69 % 39 %
Boiler fuel power (LHV), EN kJ/s 126 163 122 812 85 945 48 504
Calculated effic. acc. EN12952-15 % 89.31 89.35 88.95 88.54
Boiler fuel mass flow (EN12952-15) kg/s 13.9 13.5 9.4 5.3
t/d 1 197 1 166 816 460
Boiler fuel power (HHV), ASME kJ/s 148 811 144 858 101 348 57 187
Calculated effic. acc. ASME PTC4 % 77.37 77.40 78.52 78.51
Boiler fuel mass flow (ASME PTC4) kg/s 13.9 13.5 9.5 5.3
t/d 1 202 1 170 819 462
Boiler steam power kJ/s 115 136 112 122 79 580 44 898
Live steam mass flow kg/s 43.6 42.4 29.3 16.9
t/h 157.0 152.5 105.5 60.8
Live steam temperature °C 525.0 525.0 525.0 466.3
Live steam pressure bara 83.0 83.0 83.0 83.0
Feed water temperature °C 191.4 190.0 174.1 153.9
Feed water pressure bara 96.1 95.6 90.7 87.3

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2.17.3 Steam parameters

Case E_103BMCR E_100TMCR E_70TMCR E_40TMCR F_65TMCR F_40TMCR

STEAM TEMPERATURES Load 100 % 97 % 69 % 39 % 64 % 40 %
After 3rd superheater °C 525 525 525 472 525 496
Before 3rd superheater °C 455 456 469 435 467 457
After 2nd superheater °C 475 475 475 435 475 457
Before 2nd superheater °C 381 381 382 366 389 386
After 1st superheater °C 412 411 393 366 414 386
Drum temperature °C 306 305 302 299 301 299
Feed water after eco °C 291 290 269 248 290 267
Feed water before eco °C 191 190 174 154 170 154

Temperature drop at #2 spray °C 31 30 11 0 25 0

Temperature drop at #1 spray °C 20 19 6 0 8 0
Approach temperature °C 14 15 32 51 11 32
STEAM MASS FLOWS
Live steam flow kg/s 43.6 42.4 29.3 16.9 27.1 16.9
t/h 157.0 152.5 105.5 60.8 97.6 60.8
Spray attemperation mass flow… kg/s 2.54 2.38 0.56 0.00 0.99 0.00
...(HP circuit only) %of LS 5.8 % 5.6 % 1.9 % 0.0 % 3.6 % 0.0 %
Attemperation #1 kg/s 1.67 1.57 0.40 0.00 0.79 0.00
Blow down from drum kg/s 0.00 0.00 0.00 0.00 0.00 0.00
Feed water flow from economiser kg/s 41.1 40.0 28.7 16.9 26.1 16.9
STEAM VELOCITIES
Inside SH3 tubes, on average m/s 28.8 28.0 19.8 10.7 18.4 11.1
Inside SH2 tubes, on average m/s 23.3 22.8 16.5 9.2 15.5 9.7
Inside SH1 tubes, on average m/s 13.1 12.9 9.5 5.5 9.0 5.7
Inside economiser, on average m/s 0.8 0.7 0.5 0.3 0.5 0.3

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 Case D_103BMCR D_100TMCR D_70TMCR D_40TMCR
STEAM TEMPERATURES Load 100 % 97 % 69 % 39 %
After 3rd superheater °C 525 525 525 466
Before 3rd superheater °C 456 457 471 429
After 2nd superheater °C 475 475 475 429
Before 2nd superheater °C 380 381 382 362
After 1st superheater °C 407 406 387 362
Drum temperature °C 306 305 302 299
Feed water after eco °C 286 285 263 244
Feed water before eco °C 191 190 174 154

Temperature drop at #2 spray °C 26 25 5 0

Temperature drop at #1 spray °C 19 18 4 0
Approach temperature °C 19 20 39 55
STEAM MASS FLOWS
Live steam flow kg/s 43.6 42.4 29.3 16.9
t/h 157.0 152.5 105.5 60.8
Spray attemperation mass flow… kg/s 2.26 2.10 0.30 0.00
...(HP circuit only) %of LS 5.2 % 5.0 % 1.0 % 0.0 %
Attemperation #1 kg/s 1.43 1.34 0.19 0.00
Blow down from drum kg/s 0.00 0.00 0.00 0.00
Feed water flow from economiser kg/s 41.4 40.3 29.0 16.9
STEAM VELOCITIES
Inside SH3 tubes, on average m/s 28.8 28.1 19.9 10.5
Inside SH2 tubes, on average m/s 23.3 22.8 16.6 9.1
Inside SH1 tubes, on average m/s 13.1 12.8 9.4 5.5
Inside economiser, on average m/s 0.8 0.7 0.5 0.3

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 Case E_103BMCR E_100TMCR E_70TMCR E_40TMCR F_65TMCR F_40TMCR
STEAM SIDE PRESSURE LOSSES Load 100 % 97 % 69 % 39 % 64 % 40 %
From 3rd superheater bar 4.0 3.8 1.9 0.6 1.6 0.6
From 2nd superheater bar 2.2 2.1 1.1 0.4 0.9 0.4
From 1st superheater bar 2.5 2.4 1.3 0.4 1.1 0.5
From economiser bar 0.62 0.60 0.39 0.25 0.36 0.25
STEAM PRESSURES
After 3rd superheater bara 83.0 83.0 83.0 83.0 83.0 83.0
After 2nd superheater bara 87.5 87.2 85.1 83.7 84.8 83.7
After 1st superheater bara 90.1 89.8 86.4 84.1 85.9 84.1
Drum pressure bara 92.9 92.4 87.8 84.6 87.1 84.6
Before regulating valves bara 99.0 98.5 93.7 90.3 92.9 90.3
STEAM EFFECTS
Economiser steam effect kW 19 625 19 111 12 628 7 163 14 729 8 699
Drum steam effect kW 59 240 57 975 45 003 28 287 38 079 26 749
1st superheater steam effect kW 17 025 16 495 10 342 4 709 10 948 5 711
2nd superheater steam effect kW 11 345 10 991 7 468 3 326 6 329 3 304
Final superheater steam effect kW 7 902 7 549 4 141 1 681 3 960 1 705
Power boiler steam effect kW 115 137 112 122 79 582 45 166 74 045 46 168

Case D_103BMCR D_100TMCR D_70TMCR D_40TMCR

STEAM SIDE PRESSURE LOSSES Load 100 % 97 % 69 % 39 %
From 3rd superheater bar 4.0 3.8 1.9 0.6
From 2nd superheater bar 2.2 2.1 1.1 0.3
From 1st superheater bar 2.5 2.4 1.3 0.4
From economiser bar 0.63 0.60 0.39 0.25
STEAM PRESSURES
After 3rd superheater bara 83.0 83.0 83.0 83.0
After 2nd superheater bara 87.5 87.2 85.1 83.7
After 1st superheater bara 90.2 89.8 86.4 84.1
Drum pressure bara 92.9 92.4 87.8 84.6
Before regulating valves bara 99.1 98.6 93.7 90.3
STEAM EFFECTS
Economiser steam effect kW 18 643 18 154 11 780 6 807
Drum steam effect kW 60 765 59 455 46 363 28 643
1st superheater steam effect kW 16 523 16 008 9 885 4 468
2nd superheater steam effect kW 11 412 11 057 7 526 3 312
Final superheater steam effect kW 7 796 7 451 4 028 1 671
Power boiler steam effect kW 115 139 112 125 79 583 44 900
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2.17.4 Flue gas parameters

Case E_103BMCR E_100TMCR E_70TMCR E_40TMCR F_65TMCR F_40TMCR

FLUE GAS TEMPERATURES Load 100 % 97 % 69 % 39 % 64 % 40 %
Adiabatic combustion temperature °C 1 346 1 339 1 316 1 193 1 123 1 075
After furnace, FEGT °C 960 952 873 703 807 698
After SH2 surface °C 788 781 702 576 681 589
After SH1 surface °C 475 472 429 373 439 390
Before economiser °C 451 448 408 359 417 373
After economiser °C 244 242 216 185 224 195
After boiler °C 160 159 164 148 152 153
FLUE GAS MASS FLOWS
Mass flow, incl. recir gas kg/s 78.2 76.6 54.6 34.9 62.2 40.6
Calculated recir gas flow to bed kg/s 2.15 2.56 2.80 2.97 1.73 0.06
Flue gas density (NTP) kg/m3n 1.27 1.27 1.27 1.27 1.27 1.27
Wet volume flow, incl. recir gas m3n/s 61.7 60.4 43.1 27.5 49.2 32.0
Wet volume flow, excl. recir gas m3n/s 60.0 58.4 40.9 25.2 47.8 32.0

Flue gas velocities

After the furnace m/s 4.9 4.7 3.2 1.7 3.4 2.0
At 2nd superheater m/s 5.6 5.4 3.6 2.0 4.0 2.3
At 3rd superheater m/s 6.3 6.2 4.1 2.3 4.6 2.7
At furnace screen m/s 10.2 9.9 6.6 3.7 7.5 4.5
At 1st superheater m/s 9.8 9.5 6.3 3.6 7.3 4.4
Inside connecting duct m/s 11.5 11.2 7.5 4.5 8.7 5.3
At the beginning of eco m/s 12.0 11.7 7.9 4.7 9.1 5.6
At the end of eco m/s 8.6 8.4 5.7 3.4 6.6 4.0
At FGAP inlet m/s 11.2 10.9 7.4 4.4 8.6 5.3
At FGAP outlet m/s 10.0 9.8 6.9 4.2 7.7 4.9

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 Case D_103BMCR D_100TMCR D_70TMCR D_40TMCR
FLUE GAS TEMPERATURES Load 100 % 97 % 69 % 39 %
Adiabatic combustion temperature °C 1 393 1 385 1 378 1 228
After furnace, FEGT °C 972 964 887 704
After SH2 surface °C 791 784 703 572
After SH1 surface °C 471 468 423 369
Before economiser °C 447 444 403 356
After economiser °C 241 239 212 182
After boiler °C 158 157 161 147
FLUE GAS MASS FLOWS
Mass flow, incl. recir gas kg/s 75.4 73.9 51.9 33.7
Calculated recir gas flow to bed kg/s 3.39 3.74 2.78 3.61
Flue gas density (NTP) kg/m3n 1.28 1.28 1.28 1.28
Wet volume flow, incl. recir gas m3n/s 59.0 57.7 40.5 26.3
Wet volume flow, excl. recir gas m3n/s 56.3 54.8 38.4 23.5

Flue gas velocities

After the furnace m/s 4.7 4.6 3.0 1.6
At 2nd superheater m/s 5.4 5.2 3.4 1.9
At 3rd superheater m/s 6.1 5.9 3.8 2.2
At furnace screen m/s 9.8 9.5 6.2 3.6
At 1st superheater m/s 9.3 9.0 5.9 3.5
Inside connecting duct m/s 10.9 10.6 7.0 4.3
At the beginning of eco m/s 11.4 11.2 7.4 4.4
At the end of eco m/s 8.2 8.0 5.3 3.2
At FGAP inlet m/s 10.6 10.4 6.9 4.2
At FGAP outlet m/s 9.5 9.3 6.4 4.0

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2.17.5 Combustion air parameters

Case E_103BMCR E_100TMCR E_70TMCR E_40TMCR F_65TMCR F_40TMCR

COMBUSTION AIR Load 100 % 97 % 69 % 39 % 64 % 40 %
Combustion air moisture content g/kg dry 17.5 17.5 17.5 17.5 17.5 17.5
Ambient pressure bara 0.9 0.9 0.9 0.9 0.9 0.9
Air relative moisture content % 70.0 70.0 70.0 70.0 70.0 70.0
@temperature °C 26.0 26.0 26.0 26.0 26.0 26.0
Air temperature to boiler
Primary air °C 192.5 191.3 185.2 163.7 177.4 168.8
Overfire air °C 193.1 192.2 186.8 165.5 187.7 173.9
Combustion air flow
Primary air kg/s 21.9 21.5 15.9 10.5 24.5 16.3
m3n/s 17.1 16.8 12.5 8.2 19.1 12.8
Overfire air kg/s 38.8 37.6 25.4 15.5 21.5 15.3
m3n/s 30.3 29.4 19.9 12.2 16.8 12.0

Combustion air factor - 1.24 1.24 1.24 1.38 1.25 1.41

Flue gas oxygen content %-vol(wb) 3.10 3.10 3.10 4.50 3.10 4.50
Flue gas oxygen content %-vol(db) 4.07 4.07 4.06 5.77 4.27 6.00
Flue gas water content %-vol(wb) 23.8 23.8 23.6 21.9 27.4 25.1
Flue gas dust content g/m3n 25.6 25.5 25.5 22.4 43.2 41.2

SCAH steam consumption t/h 5.0 5.0 5.5 4.5 5.5 4.5
Ambient temperature °C 26 26 26 26 26 26

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 Case D_103BMCR D_100TMCR D_70TMCR D_40TMCR
COMBUSTION AIR Load 100 % 97 % 69 % 39 %
Combustion air moisture content g/kg dry 17.5 17.5 17.5 17.5
Ambient pressure bara 0.9 0.9 0.9 0.9
Air relative moisture content % 70.0 70.0 70.0 70.0
@temperature °C 26.0 26.0 26.0 26.0
Air temperature to boiler
Primary air °C 191.1 189.9 182.0 162.2
Overfire air °C 189.6 188.7 183.6 163.6
Combustion air flow
Primary air kg/s 19.1 18.8 15.3 9.3
m3n/s 15.0 14.7 11.9 7.3
Overfire air kg/s 39.3 38.1 24.6 15.5
m3n/s 30.7 29.8 19.2 12.2

Combustion air factor - 1.23 1.23 1.23 1.37

Flue gas oxygen content %-vol(wb) 3.10 3.10 3.10 4.50
Flue gas oxygen content %-vol(db) 3.97 3.97 3.95 5.64
Flue gas water content %-vol(wb) 21.9 21.9 21.7 20.1
Flue gas dust content g/m3n 26.0 25.8 25.7 22.6

SCAH steam consumption t/h 5.0 5.0 5.5 4.5

Ambient temperature °C 26 26 26 26

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2.17.6 Informative consumption data

The consumption data is indicative information of the process performance.

Total make-up water consumption t/d 45

of which blow-down water amount is t/d 30
of which sootblowing amount is t/d 15
3
Service air m n/h 700
3
Instrumentation air m n/h 150
MP steam consumption during normal operation kg/s N/A
LP steam consumption during normal operation (for equipment t/h 5
in ANDRITZ scope
MP steam consumption during cold start-up kg/s N/A
LP steam consumption during cold start-up (for equipment in t/h 3
ANDRITZ scope)
Diesel oil consumption during cold start-up t 12
Fresh bed material consumption (without sieve) t/d 7.0
1)
CaO consumption with semi-dry sorbent injection t/h 0.7
1) 3
Water flow, semi-dry sorbent injection m /h 10.2
Cooling water flow, bottom ash screws in oper. kg/s 18.0
Plant water (blow down tank cooling) (CW in @10°C, cooling t/h 0.8
down to 60°C)

1)
At load point “Normal 3D” in 100 % pure CaO

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2.17.7 Firing diagram

Biomass boiler
Boiler firing diagram (Solid fuel)

140
Max fuel (LHV): 10 065 kJ/kg Fuel D (LHV): 9 103 kJ/kg Fuel E (LHV): 8 141 kJ/kg Fuel F (LHV): 5 629 kJ/kg
Moist=35.0%-w Moist=40.0%-w Moist=45.0%-w Moist=50.0%-w

120 115 MWth load. Maximum continuous load (BMCR)

112 MWth load. Turbine Maximum Load (TMCR)

100
Steam power [MJ/s]

80 MWth load. Minimum full superheat with guarantee fuel

80

74 MWth load. Maximum continuous load with minimum fuel

60

40 48 MWth load. Minimum technical load

20

0
0 10 20 30 40 50 60 70

Solid fuel flow [t/h]

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BOILER START-UP CURVE, COLD START-UP

Turbine Open Turbine Turbine

ESV-line Pegging speed-up to syncronized,
heating PRDS nominal 122 min to
starts 100% load
BOILER START-UP CURVE, HOT START-UP