Waste to Energy Solutions

By
V.B. Kabra- Divisional Manager (R&D)

Thermax Babcock & Wilcox Limited - Pune India

 Fluid bed boilers Review
Multi fuel firing capabilities - In combination of high/low
ash coal or independent firing to give low cost
solutions.
BFB , IR CFBC AND PCFB
BFB : Quite matured technology for regular applications
of high/Low ash coals
Second generation developments by B&W/TBW -
Open Bottom Multi-fuel firing options and addressing
the environmental issues

IR-CFB : Third generation B&W/TBW design - High

Efficiency, compact, low maintenance, multi-fuel firing

PCFB under development stage

Fluid Bed Technology for Waste to Energy
Historically the primary solid fuel combustion technology has always been stoker
firing, before the BUBBLING FLUIDISED BED (BFB) technology emerged as
most appropriate technology for handling wide range of industrial waste.
In paper industry the paper sludge waste was normally dewaterred for handling &
volume reduction & then it used to be sent for land filling. The other waste from
paper mill like bark or wood waste used to be fired on stoker, with low
efficiency.The BFB technology has now become popular for paper mills with it’s
advantage to reduce both land fills & emissions from flue gases.
The Open Bottom Design
The unique open bottom design of B&W/TBW has distinct advantage over the
bed plate type arrangement which allows the flexibility of uniform draining from
entire bed area.
For firing fuels like paper sludge, woody bio-mass, coffee waste, high fouling
agricultural waste or high ash coals the BFB boiler must have system to drain
tramped material which comes along with the fuel, agglomerated ash of high
alkali fuels. The 100 % open bottom mounts the bubble caps on air pipes which
are evenly spaced to allow draining from the entire bed. The design provides
clear vertical path for the material to move freely to the drain area.
The following presentation details out various distinct advantages of open hopper
bottom design as well as the unique design of IR CFB.
 Fuel Analyses of Various Coals

FUEL ANALYSES
Indonasian Washery
South
Indian coal Petcoke Reject Coal Char Lignite
Coal African Coal
Fines
Moisture % 10.96 13.86 3.56 1.2 9.89 2.3 24.25
Ash Content % 30.21 5.94 18.7 5.8 21.3 63 5.15
Volatile Matter % 42.49 41.74 23.5 10 24.84 1.26 38.93
Fixed Carbon % 16.34 38.46 54.24 54.4 43.97 33.44 31.67
C% 40.61 62.05 62.5 78.8 52.9 34.2 55.23
H% 3.47 5.08 2.95 3.46 4.35 0.25 4.76
O% 16.60 25.32 10.94 11.12 10.21 0.04 21.61
Silica % 7.58 39.1 52.8 50 53.96 57.48 16.3
Iron % 10.97 13.57 4.8 13.8 14.73 9.3 10.38
Alumina % 3.26 13.87 33.8 14.9 23.65 25.78 11.42
Potassium % 0.77 1.39 0.48 0.46 0.53 0.8 0.48
Sodium % 8.94 1.93 0.94 0.72 0.23 0.4 11.17
S% 4.65 0.11 0.2 5.33 0.3 0.08 4.72
N% 0.36 0.54 1.15 0.9 1.05 0.13 0.64
GCV,kcal/kg 3765 5835 5689 7940 5595 1988 5740
 Fuel Analyses of Bio-mass Fuels

FUEL ANALYSES
Paper Liquid Coffee
Bamboo Eucaliptus Eucaliptus Paper Cotton
Julia Flora Sludge Coffee Ground
Dust Dust Bark Sludge Stalk
Viscous Waste Press
Moisture % 10.31 8.92 22.18 82.2 68.4 8.88
Ash Content % 1.15 2.1 28.95 1.68 0.3 1.38
Volatile Matter % 71.73 73.79 43.7 12.55 27.1 70.85
Fixed Carbon % 16.81 15.19 5.17 3.57 4.2 18.89
C% 49.50 34.23 26.61 16.01 14.95 21.86 8.92 20.50 8.80
H% 5.00 3.85 3.04 1.74 1.77 3.54 1.33 3.20 4.95
O% 33.29 27.18 23.49 15.36 8.49 23.34 0.71 6.48 35.24
Silica % 6.66 0.00 0.26 32.28 0.00 6.00
Chlorides % 0.05 0.34 0.07 0.07 0.22 <1 0.05 0.02
Potassium % 10.55 0.43 0.18 3.64 0.10 0.28 11.33
Sodium % 3.65 0.00 0.05 3.05 0.07 0.74 0.98
S% 0.15 0.08 0.01 0.00 0.49 0.06 0.15 0.02 0.18
N% 0.60 0.35 0.13 0.09 1.43 0.07 0.71 1.10 0.65
GCV,kcal/kg 4393 3185.70 2467 3634 1496.40 2806 3865 5300 4239
 HOPPER BOTTOM DESIGN
# Unique design of B&W (Developed for effluent /MDF firing )
which can handle the difficult , agglomerating fuels.
# Allowing uniform draining of agglomerate / clinkers through
hopper bottom.
# Ease on multiple fuel firing through over bed .
# At JOCIL - 30 tph boiler in operation since-
# Performance on the rice husk and combination fi ring with
various bio-mass fuels , observed to be quite satisfactory with
very good reliability on operation.
# Efficiency on rice husk achieved 84 % (against 82 % committed)
# For firing rice husk , coal and other bio-mass such as cotton
stalk, chilly stalk ,having high alkalis in fuel ash.( 15 to 40 %)
HOPPER BOTTOM DESIGN
BIOMASS POWER - JOCIL
OPEN HOPPER BOTTOM AFBC BOILER
• Capacity - 30 tph, 66kg cm2g, 485 Deg C,r 6MW
• Design - Open Hopper Bottom Design
• Fuels- Rice Husk, Cotton & Chilly Stalk, Juliflora etc.
• Operational since February’2001.
FEATURES
• Open Hopper Bottom - Babcock & Wilcox Unique Design
instead of conventional bed plate design.
• India’s First Multifuel biomass fired AFBC boiler
designed to handle high alkali fuels.
• Easy control of bed chemistry ensures high availability
and continues power generation
• Easy removal of agglomerates,large amount of stones
and mud ensure trouble free operation round the year
• Separate bunkers & feeders for storing and feeding
variety of fuels to meet any interruption in fuel
availability.
• High fuel flexibility ensures cost effectiveness in power
generation.
• Staggered air supply arrangement ensures complete
combustion and high thermal efficiency.
BIOMASS POWER - KHANNA PAPER
ATMOSPHERIC FLUIDIZED BED BOILER
• Capacity - 70 tph, 66kg cm2g, 485 Deg C for 15MW
• Fuels Used : Rice Husk, Padthal, etc.
FEATURES
• India’s First large capacity ricehusk / biomass fired boiler
designed to handle multiple biomass fuels with a provision for
coal.
• Proper fluidization, less chances of clinker formation or local hot
spots.
• Specially designed distributor plate - Babcock & Wilcox Design
• Adequately sized bed drain system - Controls bed inventory that
ensures high availability and continues power generation
• Easy removal of large amount of stones and mud ensure trouble
free operation round the year.
• Separate bunkers & feeders for storing and feeding variety of
fuels to meet any interruption in fuel availability.
• Staggered air supply arrangement ensures complete
combustion and high thermal efficiency.
• Multiple fuel feeding arrangement (Overbed / Under bed
options) ensures operation round the year.
BIOMASS POWER-NESTLE NANGANGUD
ATMOSPHERIC FLUIDIZED BED BOILER
Capacity - 15 tph, 24 kgf/cm2, 223 deg.cel.
Fuel - High moisture fuels such as
Spent Coffee Ground, Spent Tea Ground,
Coconut shell , Coal
Fuel feed - Over bed
Pressure parts - No inbed surfaces
Back End temperature - 140 deg C
Air preheat temp - 320 deg C
Efficiency - 62 %( 64%Moisture - M. loss alone -25%)
Emissions - NOx- 300 ppm, CO- <100 ppm

DESIGN FOR FIRING IN VARIOUS COMBINATIONS

SCG-85%M
SCG-60%M
STG70%M
Coal
Coconut shell.
B&W/ TBW IR-CFB technology
 B&W/ TBW IR-CFB technology
# High combustion efficiency
# Compact, economical design
# Higher reliability & availability
# Lower maintenance costs
# Reduced erosion
# Fuel flexibility
# Low emissions
# Lower plan area
EFB FEEDING AND FIRING ON OVERTHRUST GRATE
FLUID BED - EXPERIENCE of THERMAX

1. LOW CAPACITY PROCESS BOILERS - UP 10 TPH -

BY PROCESS HEAT DIVISION.
2. MEDIUM CAPACITY BOILERS - 10 TPH TO 30 TPH
BY ENERGY SYSTEM DIVISIONDIVISION.
3. LARGE CAPACITY BOILERS- 30 TPH AND ABOVE
BY THERMAX BABCOCK & WILCOX LTD

EXECUTED MORE THAN

900 FLUID BED BOILERS
 TBW TRAVAGRATE SPREADER STOKER

Catenary Design
Provides automatic take-up or tensioning of grate
chains.
External shaft adjustments not required.
 SIDE SEAL CASTINGS
GRATE CASTINGS

FRONT BOTTOM SEALS

SUPPORT FRAME
Grate surface
Grate surface is made in short sections- low maintenance cost
Small sections castings (230 and 300 mm).
JGC A/c Riotuba Nickel Project (Palwan Phillipines)

1 X 105 TPH, INDONESIAN COAL FIRED TRAVELLING GRATE BOILER

FLUID BED - EXPERIENCE

1. LOW CAPACITY PROCESS BOILERS - UP 10 TPH -

BY PROCESS HEAT DIVISION.
2. MEDIUM CAPACITY BOILERS - 10 TPH TO 30 TPH
BY ENERGY SYSTEM DIVISIONDIVISION.
3. LARGE CAPACITY BOILERS- 30 TPH AND ABOVE
BY THERMAX BABCOCK & WILCOX LTD

EXECUTED MORE THAN

900 FLUID BED BOILERS
 EXPERIENCE ON MULTIFUELS
Talcher Coal High Alfa Quartz Content - Very Erosive Ash
1 x 60 TPH Boiler in operation since 1996 at J K Corporation Raigada
Orissa.
2 X 110 TPH Boilers in operation at Paradeep Orissa for Oswal
Chemicals & Fertilizers. ( 55 MW CPP)
2 x 65 TPH, 93 ata under Commissioning for 1 x 30 MW CPP at Nava
Bharat Ferro Alloys Ltd.

Washery middlings Very High ash Content ( >60%)

2 x 95 TPH Boilers are in operation since 1998 at L&T Awarpur Cement
Plant ( 2 x 23 MW CPP) at Chandrapur

Grade C to F coal Wide range of Calorific value and Ash content

1 x 110 TPH Boiler in operation since 2000 at Usha Martin through L&T
(25 MW CPP) - at Jamashedpur
1 x 100 TPH, 105 ata at Karnool AP for Sri Rayalseema Allied &
Chemicals Ltd. (25 MW) under execution
 EXPERIENCE ON LIGNITE

Kutch / Rajasthan Lignite Slagging & Fouling nature of Ash

• 1 x 90 TPH, 105 ata Pressure Boiler is in operation since 1998 at
GHCL Veraval Gujarat

• 1 x 47 TPH, 47 Ksca, Boiler under commissioning at Nova Petro

Chemicals Limited, Ahmedabad.

• 1 x 70 TPH, 66 kg/cm2(g), Boiler in operation since 2002 at M/S

Khanna Paper Mills, Amritsar, Punjab.

• 2 x 80 TPH, 64 kg/cm2(g), Boilers in operation since 2002 at M/S

Shree cements limited, Beawar, Rajasthan.

• 1 x 48 TPH, 66 Ksca, Boiler under commissioning at M/S Sangam

Spinners, Rajasthan.
EXPERIENCE ON PET COKE
Petcoke Very high Sulfur >6% & very low ash <1%,
High carbon content
1. 2 x 80 TPH Petcoke & coal fired Boilers already commissioned Shree
Cement at Beawar, Rajashthan
2. 1 x 70 TPH, Pet coke, Lignite fired boiler in operation since 2002
at Khanna paper mills, Amritsar, Punjab.
3. 1 X 47 TPH lignite, coal and Petcoke fired under operation at Nova
Petro Chemicals Ahmedabad.
4. 1 x 48 TPH coal and Petcoke fired boiler under commissioing
at Sangam Spinners, Bhilwara,Rajasthan
5. 1 x 50 TPH rice husk, coal and Petcoke fired Boiler under execution
for Chaddha Paper, Rampur UP
6. 2 x 45 TPH, Imported coal, Rice husk and Petcoke fired under
execution for Gujarat Ambuja Cement (Ropar unit)
7. 1 x 100 TPH, Pet coke, Lignite, Paper sludge and plastic waste fired
boiler is under execution at Khanna paper mills, Amritsar, Punjab.
 EXPERIENCE ON AGRO WASTE

Rice Husk Agro waste fuel

1 x 70 TPH Rice Husk fired Boiler at Khanna Paper Amritsar

1 x 35 TPH Rice Husk and coal fired boiler at JCT Ltd. Phagwara

1 x 30 TPH Boiler in operation since 2001at Dokiparru AP for Jocil Ltd

1 x 35 TPH Boiler in operation since 2003 at Saro Power Ltd. AP

EXPERIENCE ON BIOMASS

Biomass Juli Flora, Cotton stalk, Coconut Shell,

Mustered Husk, etc

1 x 30 TPH Boiler in operation since 2001at Dokiparru AP for Jocil Ltd

1 x 35 TPH Boiler in operation since 2003 at Saro Power Ltd. AP

Coffee Ground Very high moisture- > 85%

1 x 18 TPH Boiler in operation for > 5 years at Nestle Ltd, Nanjangud,
Karnataka
1 x 15 TPH Boiler under execution for Nestle (Quality Coffee Thailand)
1 x 17 TPH Boiler under execution for Nestle - Russia
EXPERIENCE ON HOPPER BOTTOM FLUID BED
Biomass Julia Flora, Cotton stalk, Coconut Shell,
Mustered Husk, etc

1 x 30 TPH Boiler in operation since 2001at Dokiparru AP for Jocil Ltd

1 x 35 TPH Boiler in operation since 2003 at Saro Power Ltd. AP

1 x 85 TPH, 87 ata, coal and Char Fired AFBC boiler for Bhushan
Steels Orissa

1 x 100 TPH, Pet coke, Lignite, Paper sludge and plastic waste fired
boiler is under execution at Khanna paper mills, Amritsar, Punjab.

Coffee Ground Very high moisture- > 85%

1 x 17 TPH Boiler under execution for Nestle - Russia

 EXPERIENCE IN STEEL INDUSTRY

Steel Industry

1 X 110 TPH, 66 kg/cm2(g) Boiler in operation at M/S Usha Martin

Industries Limited, Jamshedpur. ( 25 MW CPP)

2 X 110 TPH, 66 kg/cm2(g) Boilers in operation at Paradeep Orissa for

Oswal Chemicals & Fertilizers. ( 55 MW CPP)

2 x 65 TPH, 93 ata boilers in operation at Nava Bharat Ferro Alloys Ltd.

(30 MW CPP)

1 x 85 TPH, 87 ata Hopper bottom design, coal and Char Fired AFBC
boiler for Bhushan Steels Orissa
TBW’s Experience -CFBC Boiler Technology in India.
B&W Design Internal Re-circulation CFB Boiler with SS U beams as
primary solids separator.

1 x 105 TPH, 67 ata 480°C high ash coal fired CFB boiler at Kanoria
Chemicals Renukoot UP. In operation since 1997.