ISGEC John Thompson

DESIGN ASPECTS OF
CIRCULATING FLUIDIZED
BED COMBUSTION BOILER
 ISGEC John Thompson

Basics of Fluidisation
Fluidisation is originated from the word “FLUID” or ability to flow.
In a fluidised bed all properties of fluids are incorporated like :
-Fluid flows due to elevation difference.
-It maintains horizontal level
-It exerts pressure at bottom proportional to the height of column
-It attains shape of vessel in which it is stored.
-If two vessels are connected, a common level is maintained.
-The molecules can move without requirement of any external energy
randomly inside the boundary of the liquid ( Brownian motion).
-The molecules can not leave the boundary unless they reach the
saturation temperature.

In a fluidised bed, the particles of bed material attains all the above
properties of the fluids.
 ISGEC John Thompson

Basics of Fluidisation
In a fluidised bed, the particles of bed material attains all the above
properties of the fluids.

Consider a particle of bed material in non fluidised state. It exerts a

downwards force equal to its weight and hence can not move. If a stream
of air is allowed to flow below this particle, it experiences a upward drag
force equal to pressure of air x its cross section area. If we go on
increasing the air pressure, a time will come when the drag force balances
the weight of the particle and it will come in weightless condition and now it
is free to move anywhere inside the bed without any additional energy.
Now the bed attains all the properties of a fluid and experiences a very
high turbulence and mixing.

This indicates that fluidisation system is highly sensitive to particle weight/

size. Every system has its unique fluidisation velocity and the performance
changes with change in particle size.
Principle ofJohn
fluidization
Thompson
ISGEC

 Evenly distributed air is passed

upward through a finely divided bed
of 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. Further, increase in
velocity gives rise to bubble
formation, vigorous turbulence and
rapid mixing.

 The bed of solid particles exhibits the

properties of a boiling liquid. This
state is called be fluidized.
 Combustion takes place at about
840OC to 950OC.
CirculatingISGEC
fluidized bed.
John Thompson

With higher air velocities, the bed

particles leave the combustion with
the flue gases so that solids
recirculation is necessary to maintain
circulating fluidized bed.

The mean solids velocity increases at

a slower rate than does the gas
velocity, as illustrated in Figure

Therefore, a maximum slip velocity

between the solids and the gas can be
achieved resulting in good heat
transfer and contact time with the
limestone, for sulfur dioxide
removal. Relation between gas velocity and solid velocity
AFBC or Bubbling Bed
ISGEC John Thompson

Features of bubbling bed boiler

 AFBC use the in-bed evaporator tubes

for extracting the heat from the bed to
maintain the bed temperature.
 The bubbling bed has heat transfer tubes
in the bed of limestone, sand and fuel.
The velocity of fluidising air is in the
range of 1.2 to 3.7 m /sec. Very little
material leaves the bubbling bed – about
2 to 4 kgs of solids are recycled per kg
of fuel burned.
 The bed depth is usually 0.9 m to 1.5
meter deep and the pressure drop
averages about 1 inch of water per inch
of bed depth.
Features of John
bubbling
Thompson
ISGEC bed boiler

 Coal is crushed to a size of 1 – 6 mm (depending on coal

characteristics) and fed to the combustion chamber.
 The atmospheric air, which acts as both the fluidization air and
combustion air, is delivered at a pressure, and flows through the
bed after being preheated by the exhaust flue gases. The in-bed
tubes carrying water generally act as the evaporator.
 If temperature exceeds 950oC , there is risk of clinker formation in
the bed and combustion efficiency declines below 800oC.
 For efficient sulphur retention the temperature should be in the
range of 800oC to 850oC.
 ISGEC John Thompson

FUNDAMENTALS OF CIRCULATING
FLUIDIZED BED BOILER (CFBC)

 CFBC boiler is a device for generating steam by

burning fossil fuel in a furnace operated under a
special hydrodynamic conditions where fine
solids are transported through a furnace at a
velocity exceeding free fall velocity of individual
particles.
 The major fraction of the solids entrained out of
the vessel is captured by a cyclone separator
and is circulated back to a point near the base
of furnace at sufficiently high rate to cause
refluxing of solid in furnace. Creation of special
 ISGEC John Thompson

FUNDAMENTALS OF CIRCULATING
FLUIDIZED BED BOILER (CFBC)
 A certain combination of gas velocity, recirculation rate,
solid characteristics, volume of the solids, geometry of the
system gives rise to this special hydrodynamic condition
where solid particles are subjected to a upward velocity
greater than free falling velocity of most individual particles.
Solids are moved up & down in groups called clusters.
 Clusters move vertically, sideways, as well as down wards.
They are continuously formed dissolved & reformed again.
 Fuel particle burn generating heat. Part of heat is extracted
by water/steam surfaces located in the furnace at very high
heat transfer rate.
 ISGEC John Thompson

BASICS OF CIRCULATING FLUIDIZED BED COMBUSTION

 CFB, uses greater combustor superficial gas velocities than
the BFB.
 CFB operates under a special fluid dynamic condition, in
which the fine solids particles are transported and mixed
through the furnace at a gas velocity exceeding the average
terminal velocity of the particles. The major fraction of solids
leaving the furnace is captured by a solids separator and
recirculated back to the base of the furnace. The high recycle
rate intensifies solids mixing and evens out combustion
temperatures in the furnace.
 CFB systems operate in a fluid dynamic region between that of
BFB and a transport reactor (pulverized combustion). This
fluidization regime is characterized by high turbulence, solid
mixing and the absence of a defined bed level. Instead of a
well‑defined solids bed depth, the solids are distributed
throughout the furnace with a steadily decreasing density from
the bottom to the top of the furnace.
 ISGEC John Thompson

CFB is characterized by:

* High fluidizing velocity of 4.0 -6.0 m/s (13 – 20 ft/s).

* Dense bed region in lower furnace without a distinct
bed level
* Water-cooled membrane walls.
* Optional in-furnace heat transfer surfaces located above
the dense lower bed
* Solids separator to separate entrained particles from the
flue gas stream and recycle them to the lower furnace.
* Aerated sealing device, loop seal, which permits return
of collected solids back to the furnace
 ISGEC John Thompson

CFB Separator
 A solids separator located at the outlet of the combustion chamber
separates entrained particles from the flue gas stream. The separator
is designed for a very high solid collection efficiency with nearly 100
per cent efficiency for particles greater than 60 microns in diameter.

 The collected solids are returned to the combustion chamber via the
loop seal, which provides a pressure seal between the positive
pressure in the lower furnace and the negative draft in the solids
separator. This prevents the furnace flue gas from short circuiting up
the separator dipleg and collapsing the separator collection efficiency.
The recirculation system has no moving parts and its operation has
proven to be simple and reliable. By injecting small amounts of high
pressure fluidizing air into the loop seal, the solids movement back to
the lower furnace is maintained.
Circulating John
Fluidised
ISGEC Thompson Bed Combustion
(CFBC)
 (1- 6 mm size) fuel and limestone are injected into the
furnace
 The particles are suspended in a stream of upwardly
flowing air (60-70% of the total air), which enters the
bottom of the furnace through air distribution nozzles.
The balance of combustion air is admitted above the
bottom of the furnace as secondary air.
 While combustion takes place at 840-980oC, the fine
particles (<450 microns) are elutriated out of the
furnace with flue gas velocity of 4-6 m/s. The particles
are then collected by the solids separators and
circulated back into the furnace. This combustion
process is called circulating fluidized bed (CFB).
Circulating John
Fluidised
ISGEC Thompson Bed Combustion
(CFBC)
 There are no steam generations tube immersed
in the bed. Generation and super heating of
steam takes place in the convection section,
water walls, at the exit of the riser.
 CFBC boilers are generally more economical
than AFBC boilers for industrial application
requiring more than 75 – 100 T/hr of steam.
performance of CFBC
ISGEC John Thompson

 The temperature of about 870oC is reasonably constant throughout the process

because of the high turbulence and circulation of solids. The low combustion
temperature also results in minimal NOx formation.
 Sulfur present in the fuel is retained in the circulating solids in the form of
calcium sulphate is removed in solid form. The use of limestone or dolomite
sorbents allows a higher sulfur retention rate, and limestone requirements have
been demonstrated to be substantially less than with bubbling bed combustor.
 The combustion air is supplied at 1.5 to 2 psig rather than 3-5 psig as required
by bubbling bed combustors.
 It has high combustion efficiency.
 It has a better turndown ratio than bubbling bed systems.
Advantages ofThompson
ISGEC John Cirulating Fluidised Bed
Combustion Boilers
High Efficiency:
Reduction in Boiler Size:.
Fuel Flexiblity: Fuels like washer rejects, agro waste can be burnt efficiently.
Boilers can fire coals with ash content as high as 62% and having calorific value
as low as 2,500 kcal/kg.
Pollution Control;SO2 formation can be greatly minimised by addition of
limestone or dolomite for high sulphur coals. Eliminates NO x formation.
Low Corrosion and Erosion:are less due to lower combustion temperature,
softness of ash and low particle velocity (of the order of 1 m/sec).
No Clinker Formation : temperature of the furnace is in the range of 750–900 o C.

Less Excess Air – Higher CO2 in Flue Gas:20 – 25% excess air only.
No Slagging in the Furnace-No Soot Blowing: volatilisation of alkali
components in ash does not take place and the ash is non stocky.
 ISGEC John Thompson

ADVANTAGES OF CFBC
 FUEL FLEXIBILITY - CFBC BOILER CAN BURN A WIDE RANGE
OF FUELS WITH GOOD EFFICIENCY WITH OUT MUCH CHANGE
IN HARDWARES OF THE FURNACE
 HIGH COMBUSTION EFFICIENCY - IT CAN BURN FUEL
PARTICLES OF WIDE SIZE WITH VERY HIGH COMBUSTION
EFFICIENCY OF 98%
 LOW AIR POLLUTION - NOX EMISSION IS BELOW ACCEPTABLE
LIMIT. IT CAN REDUCE SOX EMISSION BY 95% WITH MINIMUM
USE OF LIMESTONE
 GOOD TURNDOWN CAPABILITY - IT CAN RESPOND
FLUCTUATING LOAD DEMAND MUCH EASILY

 SMALLER FEED POINTS - IT REQUIRES ONLY A FRACTION OF

FEED POINTS OF AN AFBC BOILER OF SIMILAR SIZE WOULD
REQUIRE.
 ISGEC John Thompson

SPECIAL COMPONENTS OF CFBC BOILERS

- COMBUSTOR
- COMPACT SEPARATOR
- STEAM COOLED CONVECTION CAGE

- BOTTOM ASH REMOVAL SYSTEM – STRIPPER COOLER

- FUEL FEEDING SYSTEM

- AIR DISTRIBUTION SYSTEM

 ISGEC John Thompson

COMBUSTOR
- CONSISTS OF MEMBRANE WALL GAS TIGHT
ENCLOSURE DESIGNED TO CONTAIN A SLIGHT
POSITIVE PRESSURE

- LOWER COMBUSTION CHAMBER FLOOR HAS AN AIR

DISTRIBUTION GRID FOR INTRODUCING PRIMARY AIR

- THERE IS NO HEAT TRANSFER TUBES IMMERSED IN

THE BED

- IN LOWER PORTION WHERE RAPID CHANGE FOR SOLD

FLOW PATTERN OCCURS THERE WALL TUBING ARE
PROTECTED BY THIN LAYER OF REFRACTORY.

- LOWER COMBUSTOR HAS OPENINGS FOR PRIMARY &

SECONDARY AIR PARTS, BURNERS, FUEL, LIMESTONE
AND BED MATERIAL FEED POINTS ETC.
 ISGEC John Thompson

COMBUSTOR
- FUEL FED INTO LOWER COMBUSTOR MIX QUICKLY AND
UNIFORMLY WITH BED MATERIAL, HENCE THERE IS NO
VISIBLE BED LEVEL. BED DENSITY DECREASES
PROGRESSIVELY WITH HEIGHT.

- ON FUEL LOAD OPERATION ABOUT 40 - 50% OF HEAT

GENERATED BY COMBUSTION IS ABSORBED BY WALL

- HIGH CIRCULATING SOLIDS AND BACK MIXING

INTENSITY PROVIDE HIGH HEAT TRANSFER RATE.

- AMOUNT OF PRIMARY AIR NEEDED INITIAL

FLUIDISATION OF BED MATERIAL HAS TO BE
MAINTAINED UNDER ALL CONDITIONS.
 ISGEC John Thompson

COMBUSTOR

- DISTRIBUTION OF AIR BETWEEN PRIMARY AND

SECONDARY AIR IS IMPORTANT TO AVOID
EXCESSIVELY HIGH TEMPERATURE IN THE LOWER
COMBUSTION CHAMBER, TO ENSURE GOOD
COMBUSTION EFFICIENCY AS WELL AS LOW NOX
PRODUCTION.
ISGEC John Thompson

Kick Out
Arrangement
The transition zone in the
lower furnace is provided
with a special arrangement
called Kick-out to eliminate
erosion of the furnace wall
tubes due to impingement
of bed material.
 ISGEC John Thompson

COMPACT CYCLONE
- CYCLONE IS A VITAL PART OF CFBC BOILER
- CYCLONE IS DESIGNED TO PROVIDE EFFICIENT
SEPARATION OF ENTRANCED SOLIDS FROM THE HOT
FLUE GAS AND RETURN MOST OF THE UNBURNED
CARBON AND CALCINED LIMESTONE FOR BETTER USE
ALONG WITH INERT ASH PARTICLES.
- CYCLONE SEPARATES PARTICLES GREATER THAN 60
MICRONS WITH 99.5% EFFICIENCY.
- SOLID CAPTURED IN CYCLONE ARE RECIRCULATED
BACK TO COMBUSTION CHAMBER THROUGH A
SPECIAL NON MECHANICAL LOOP SEAL.

- SOLID FLOW IN THE LOOP SEAL IS MAINTAINED

RELIABLY BY FLUIDISATION WITH A SMALL AMOUNT
OF HIGH PRESSURE AIR.
- THERE IS NO MOVING MECHANICAL PARTS IN LOOP
SEAL.
 ISGEC John Thompson

Steam Cooled Convection Cage

Acts as an
enclosure for
Super heaters
 ISGEC John Thompson

BOTTOM ASH REMOVAL SYSTEM

- TO MAINTAIN THE CONSTANT BED MATERIAL
INVENTORY IN THE FURNACE, BOTTOM ASH REMOVAL
RATE SHALL BE CONTROLLED BY SUITABLE SYSTEM

- WE HAVE PROVIDED STRIPPER ASH COOLERS FOR

ABOVE PURPOSE.

- IN ADDITION TO BOTTOM ASH REMOVAL THIS SYSTEM

PERFORMS FOLLOWING FUNCTIONS.

 PROVIDES COOLING OF BOTTOM ASH MATERIAL

 CLASSIFIES THE BOTTOM ASH MATERIAL AND RETURN

LIGHT PARTICLES TO MAINTAIN FURNACE BED
QUALITY

 RECOVERS HEAT FROM ASH

 RECOVERS FINE UNBURNT CARBON

 ISGEC John Thompson

AIR DISTRIBUTION
- IN ORDER TO ENSURE THE COMBUSTION AS
COMPLETE AS POSSIBLE 20% EXCESS AIR AT 100%
MCR SHALL BE PROVIDED.

- IN CFBC BOILERS THE AIR SUPPLIED ARE DIVIDED

INTO

PRIMARY AIR - SUPPLIED THROUGH FLOOR GRID

AND PARTLY THROUGH OSM
ABOVE
GRID

SECONDARY AIR - COMPRISES OF AIR SUPPLIED

THROUGH
SECONDARY AIR
NOZZLES, AIR FOR FUEL FEED,
LOOP SEAL
FLUIDISING, BURNER
COOLING ETC.
 ISGEC John Thompson

AIR DISTRIBUTION
- HIGHER VOLATILE FUEL BURN HIGHER IN THE
FURNACE AND REQUIRES LESS PRIMARY AIR TO KEEP
THE LOWER BED COOL.

- LOW VOLATILE FUELS REQUIRE MORE PRIMARY AIR

AS COMBUSTION TAKES PLACE IN LOWER BED.

- IN MULTI FUEL APPLICATIONS BOTH EXTREME CASES

ARE TO BE CONSIDERED FOR DESIGN.
ISGEC John Thompson

Air
Distribution
for Different
Fuels