cfb presn-ntpc11.07.06
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Presentation on CFBC Boilers
FBC & HRSGBharat Heavy Electricals Limited TIRUCHIRAPALLI
Welcometo
Presentationon
CFBC Boilers
Presentation on CFBC Boilers
FBC & HRSGBharat Heavy Electricals Limited TIRUCHIRAPALLI
CFBC Development Journey• Test Facility installed – 1991
• Collaboration with LLB ( LEE ) – 1993
• Technology transfer/Training of Engineers - 1996
• First non –reheat boiler (175 t/h ) installed at BILT , Bhigwan - 1998
• First Utility reheat boiler ( 2x125 MW ) installed at SLPP , Mangrol - 1999
• Testing of Lignite – 2001
• 125 MW order received from RVUNL, Giral – 2003
• 75 MW order received from GEB, Kutch – 2004
• 2 x 135 t/h order received from M/s Gujarat Ambuja cement - 2004
• 2 x 250 MW order received from Neyveli Lignite Corporation – 2005
• 125 MW repeat order received from RVUNL, Giral – 2005
• 2 x 125 MW order received from NLC – Barsingsar firing Rajasthan Lignite– Oct 2005
• 2 x 125 MW repeat order received from SLPP – March 2006
Presentation on CFBC Boilers
FBC & HRSGBharat Heavy Electricals Limited TIRUCHIRAPALLI
Basic Flow Diagram of CFBC Boiler
ID Fan
SECONDARYAIR
Presentation on CFBC Boilers
FBC & HRSGBharat Heavy Electricals Limited TIRUCHIRAPALLI
Advantages of CFBC
Simplified Fuel Preparation and feeding (No Pulveriser) In-Situ SOx and NOx control Oil support for load below 30% and start up only Slag-Free Combustion. Dry ash powder only FSSS avoided. Burner Management for Start-Up Burner
only Lower Temperature / Less Intense (no flame)
Combustor Environment Suitable for using wide range of fuels in the same boiler Suitable for fuels which are difficult to burn High Carbon Burn-out (Very low carbon in ash)
Presentation on CFBC Boilers
FBC & HRSGBharat Heavy Electricals Limited TIRUCHIRAPALLI
Why Fluid Bed Combustion ?
Presentation on CFBC Boilers
FBC & HRSGBharat Heavy Electricals Limited TIRUCHIRAPALLI
SOx Control
• 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
Presentation on CFBC Boilers
FBC & HRSGBharat Heavy Electricals Limited TIRUCHIRAPALLI
SOSO22 Control Reactions Control Reactions
• Straightforward method - Limestone addition along with fuel into combustor
• Reactions
S + O2 SO2
CaCO3 CaO + CO2 (Calcination)
CaO + SO2 + 1/2 O2 CaSO4 (Sulphation)
Presentation on CFBC Boilers
FBC & HRSGBharat Heavy Electricals Limited TIRUCHIRAPALLI
Limestone Requirement Limestone Requirement
Temperature
Lim
esto
ne R
equi
rem
ent
Presentation on CFBC Boilers
FBC & HRSGBharat Heavy Electricals Limited TIRUCHIRAPALLI
Formation of NOx and Control
• 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
Presentation on CFBC Boilers
FBC & HRSGBharat Heavy Electricals Limited TIRUCHIRAPALLI
Spiess Valve
Advantages of FBHE
Presentation on CFBC Boilers
FBC & HRSGBharat Heavy Electricals Limited TIRUCHIRAPALLI
Distinct Advantages of FBHE
Elimination of heat transfer bundle / panel in combustor
Very Low carbon in ash and Limestone consumption even at part load due to Optimum combustor temperature (about 850 Deg C )
Better fuel flexibility due to provision for adjusting heat absorption
Higher efficiency and reduced NOx emission even at part load due to constant excess air
Unique RH temperature control option
Presentation on CFBC Boilers
FBC & HRSGBharat Heavy Electricals Limited TIRUCHIRAPALLI
Fuel Quality / Load
Com
b.
Tem
p.
Hea
t d
uty
Combustor
Conv. Pass
With FBHE
FBHE
Without FBHE
Presentation on CFBC Boilers
FBC & HRSGBharat Heavy Electricals Limited TIRUCHIRAPALLI
• Fuel Coal (Imported+Indian)
• Commissioned March 1998
• Total hours logged 65,000
• Minimum load achieved
(without Oil support) 20 % MCR
• Controllability Range (achieved) 30 to 100%
• Generally in Continuous operation between planned annual stoppages
SINARMAS 175 t/h CFBC Boiler
Presentation on CFBC Boilers
FBC & HRSGBharat Heavy Electricals Limited TIRUCHIRAPALLI
Arrangement (Elevation) of Bilt Graphics CFBC Boiler
Presentation on CFBC Boilers
FBC & HRSGBharat Heavy Electricals Limited TIRUCHIRAPALLI
Location : Mangrol , Surat Dt , Gujarat
Fuel : Lignite ( 50 % M & 2.5 %S)
HHV - 2500 to 5500
Total hours logged : 65,000
Boiler Parameters
SH Steam : 390 T/H, 132 ATA, 540 0C
RH Steam : 350 T/H, 32.5 ATA, 540 0C
SLPP 2 x 125 MW CFBC BOILER
Presentation on CFBC Boilers
FBC & HRSGBharat Heavy Electricals Limited TIRUCHIRAPALLI
Arrangement (Plan) of SLPP CFBC Boiler
Presentation on CFBC Boilers
FBC & HRSGBharat Heavy Electricals Limited TIRUCHIRAPALLI
Arrangement (Elevation) of SLPP CFBC Boiler
Presentation on CFBC Boilers
FBC & HRSGBharat Heavy Electricals Limited TIRUCHIRAPALLI
View of 2 x 125 MWe SLPP
Presentation on CFBC Boilers
FBC & HRSGBharat Heavy Electricals Limited TIRUCHIRAPALLI
SLPP - Lignites Used
Fuel Design Actual
Fixed Carbon % 14 - 40 18 - 33Volatile Matter % 25 - 44 21 - 26Moisture % 10 - 50 41 - 48Ash % 7 - 48 4 - 8Sulphur* % 0.36 – 2.5 0.3 - 2
HHV kcal/kg 2500 -5500 2300 - 4775
Presentation on CFBC Boilers
FBC & HRSGBharat Heavy Electricals Limited TIRUCHIRAPALLI
SLPP Performance
Fuel Design Actual
Carbon % 43.30 30.75Hydrogen % 3.14 3.48Sulphur % 1.20 (2.5) 1.18Nitrogen % 0.81 0.43Oxygen (by diff.) % 8.53 7.61Moisture % 24.00 42.44Ash % 19.02 14.10
HHV kcal/kg 4250 3090Chlorine content in Lignite Not identified 0.3-0.4%
Presentation on CFBC Boilers
FBC & HRSGBharat Heavy Electricals Limited TIRUCHIRAPALLI
RVUNL – Giral 125 MW
Presentation on CFBC Boilers
FBC & HRSGBharat Heavy Electricals Limited TIRUCHIRAPALLI
Comparison of SLPP – Giral (Boiler parameters )
Parameter Unit SLPP Giral
Unit Rating MW 125 125
Type of Circulation Natural Natural
SH/RH Flow t/h 390 / 350 405 / 336
SH/RH Pres. kg/cm2 132 / 30.5 132 / 34
SH/RH Tem. Deg C 540 / 540 540 / 540
FW Tem. Deg C 235 237
Presentation on CFBC Boilers
FBC & HRSGBharat Heavy Electricals Limited TIRUCHIRAPALLI
Lignite Analysis - ComparisonSLPP Giral
Proximate Analysis (% by weight) Moisture 24 10-50 40
Ash 19.02 7-48 15Volatile Matter 32.52 25-44 20Fixed Carbon (by diff.) 24.46 14-40 25HHV, kcal/kg 4240 2500-5500 3000
Ultimate Analysis (% by weight)Carbon 43.330.09Hydrogen 3.14 2.24Sulphur 1.2 (max 2.5) 6.00Oxygen 8.55 6.27Nitrogen 0.81 0.4Moisture 24.0 40.0Ash 19.02 15.0
Presentation on CFBC Boilers
FBC & HRSGBharat Heavy Electricals Limited TIRUCHIRAPALLI
Limestone Analysis - Comparison
SLPP GiralAnalysis (% by weight)
CaCO3 85.23 96.8
MgCO3 1.18 1.2SiO2 8.65 1.15Moisture 2.05 0.28Others 2.89 0.57
Presentation on CFBC Boilers
FBC & HRSGBharat Heavy Electricals Limited TIRUCHIRAPALLI
Giral – Design Evolution
Presentation on CFBC Boilers
FBC & HRSGBharat Heavy Electricals Limited TIRUCHIRAPALLI
Giral CFBC Boiler Design - Evolution
• About 50 feedbacks from the operational experience from SLPP and BILT Graphics
• Learnings from 158 SARs from SLPP and Bilt Graphics incorporated
• Discussions with Manufacturing and OP&C groups
• Discussions with Erection Group - PSWR
Presentation on CFBC Boilers
FBC & HRSGBharat Heavy Electricals Limited TIRUCHIRAPALLI
250 MW CFBC Flow Schematic
Presentation on CFBC Boilers
FBC & HRSGBharat Heavy Electricals Limited TIRUCHIRAPALLI
250 MW CFBC Boiler
CONVECTIVE PASS
CYCLONES
SEC. APH( REGEN )
FBHE
SPECIALCOMBUSTOR
COAL BUNKERS
Presentation on CFBC Boilers
FBC & HRSGBharat Heavy Electricals Limited TIRUCHIRAPALLI
General Arrangement of 250 MW CFBC boiler
Presentation on CFBC Boilers
FBC & HRSGBharat Heavy Electricals Limited TIRUCHIRAPALLI
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