Circulating

Fluidized
Bed Boiler

03/27/2021 Gyanendra Sharma, NPTI Delhi

 • Future utilization of oil and coal in utility and industrial power
stations depend on combustion systems which meet the
requirement of an extensive reduction of emission

• One solution with economical benefits is:

Circulating Fluidized Bed Combustion

03/27/2021 Gyanendra Sharma, NPTI Delhi

001 656p
 History

Two CFB technologies have been developed

• One origin was a bubbling bed burning low grade fuels
• The other origin were gas/solid reactors for process technology applications

End of 70ies first applications in coal combustion

Break through
• in the 80ies due to environmental legislation
Typically 200 mg/m³ NOX and 200 - 1,000 mg/m³ SO2 became mandatory
• later due to utilisation of opportunity fuels

03/27/2021 Gyanendra Sharma, NPTI Delhi

141 267p
 Relationships
between Fixed Grate, Fluidized Bed, and
Pulverized Firing
S to k e r F ir in g F lu id iz e d B e d F ir in g P u lv e r iz e d F irin g
(F ix e d B e d ) BFB C FB (E n tr a in e d B e d )

G as
G as
G as
G as

Fu e l Fu e l & A ir A ir
S o rb e n t Fu e l & Fu e l
S o rb e n t

A ir A s h A ir A s h A ir A s h A sh

V e lo c ity 8 - 1 0 ft/ s e c 4 - 1 0 ft/ s e c 1 5 - 2 3 ft/ s e c 1 5 - 3 3 ft/ s e c

(2 .3 - 3 .0 m / s ) (1 .2 - 3 .0 m / s ) (4 .6 - 7 .0 m / s ) (4 .6 - 1 0 .0 m / s )

A ve ra g e Be d
6 ,0 0 0 m 1 ,0 0 0 m 1 0 0 - 3 0 0 m 5 0 m
P a r tic le S iz e
03/27/2021 Gyanendra Sharma, NPTI Delhi
056 338p
 CFB technology generates power :

 Environmentally friendly

 High SO2 capture

 Low NOx emissions

 Firing a wide variety of different fuels

03/27/2021 Gyanendra Sharma, NPTI Delhi

 SO2 Capture

 SO2 Capture achieved by Optimum temperature :

850 °C
limestone injection
SO2Capture efficiency
CaCO3 --> CaO + CO2

CaO + SO2 + ½ O2 --> Ca SO4

Furnace temperature control is

very critical

Limestone consumption varies 800 850 900

enormously with furnace temperature T (°C)

03/27/2021 Gyanendra Sharma, NPTI Delhi

 NOx Emissions

 NOx Emissions influenced by

3 main parameters :

NOx

- Combustion temperature

- N2 in fuel

- Excess air and staggering T (°C)

800 1 000 1 200

03/27/2021 Gyanendra Sharma, NPTI Delhi

 General Process

Flue gas

 Bed temperature

Optimum
temperature :
850 °C

Coal

Temperature maintained by heat

pick up in exchange surfaces

Either in furnace

Or in FBHE
Air Air

Ash

Air
03/27/2021 Gyanendra Sharma, NPTI Delhi
 CFB Boilers

1
8

7 9
3
2

03/27/2021 Gyanendra Sharma, NPTI Delhi

 Concept

Main Design Criteria

 High bed inventory of fine particles

 High recirculation rate

 Highly efficient cyclones

 External and/or Internal heat exchangers for temperature control

depending upon the application

03/27/2021 Gyanendra Sharma, NPTI Delhi

 Concept

External Heat Exchangers

Advisable when :

 A very fine tuning of the bed temperature is necessary

 Fuel Analysis leads a small furnace

( Petroleum coke , Anthracites )

 Very large electrical capacity CFB

 Highly abrasive fuels

03/27/2021 Gyanendra Sharma, NPTI Delhi

 FBHE Design

Cyclone Furnace

FBHE

03/27/2021 Gyanendra Sharma, NPTI Delhi

 FBHE Design

Ashes from
Ashes to cyclones
furnace

03/27/2021
Fluidisation air
Gyanendra Sharma, NPTI Delhi
 Wing Walls

to cyclone

Could be used as
• Evaporator
• HP superheater
• Final reheater

Tube -fin-tube
de sign

Erosion prote ction

(re fra tory)

Furna ce
03/27/2021 Gyanendra Sharma, NPTI Delhi
 Omega Panels

View from top

Platen heaters within the furnace are a powerful

feature:

• To extract heat for superheating from the furnace

• To have a self controlling system for furnace heat
extraction (no mechanical control means needed)
• To avoid erosion of heating surfaces by installation in
the vertical flow area of the furnace and smooth surface
design

First unit has now gathered more than 100 000 h

operation with first platen heater equipment.

Double Super Welded Design

Omega Design

03/27/2021 Gyanendra Sharma, NPTI Delhi

 CFD Analysis
of Cyclone
Performance

03/27/2021 Gyanendra Sharma, NPTI Delhi

006 056px
 Fractional Collection
Efficiency of Collection
Systems
(Results from Simulation)
120%

100%

80%
Collection efficiency

Cyclone

60%

40%
a lte rna tive colle ction syste m
20%

0%
0 50 100 150 200 250
d [µm ]
03/27/2021 Gyanendra Sharma, NPTI Delhi
056 287p
 Cyclone Improvement
Measures Se cond Pa ss
Ecce ntric Vorte x
Finde r Arra nge me nt
Downwa rd
Incline d Adva nce d Vorte x
Inle t Duct Finde r Sha pe

High Pe rforma nce

Re fra ctory for Inle t Are a

03/27/2021 Gyanendra Sharma, NPTI Delhi

056 329p
 Particle Size
Distribution
ofNew
(Old and
0.1
Solid
CycloneInventory
Design)
1.0
ne w cyclone de sign old cyclone de sign
(%)
1 0.0
2 0.0
3 0.0
4 0.0
5 0.0
6 0.0
7 0.0
8 0.0
Re sidue R

9 0.0

9 9.0

9 9.9
10 1 00 µm 1000
03/27/2021 Gra in NPTI
Gyanendra Sharma, size dDelhi
056 330p
 High Efficient Cyclone
Benefits
• Maximize fine solid recirculation

• Increase carbon burnout as well as limestone utilization

• Increasing solid concentration in the upper furnace leads to

• enhanced heat transfer
• perfect temperature homogenity

• Fine PSD of inventory and thus less erosions

• Minimize solids entrained to the backpass and thus

• less backpass erosion
• less backpass fouling
• lower CO generated in the backpass
03/27/2021 Gyanendra Sharma, NPTI Delhi
056 343p
 Cyclone Arrangements
< 1 00 MWe l 10 0 - 2 00 MWe l

20 0 - 30 0 MWe l 3 0 0 MW - 4 00 MWe l 6 0 0 MWe l

03/27/2021 Gyanendra Sharma, NPTI Delhi

056 352p
 125 MWe, 250 MWe and Beyond

+ + +
+ +
+ +

+ +

+ + +

Class 150 MW Class 350 MW Class 600 MW

03/27/2021 Gyanendra Sharma, NPTI Delhi

 Performance of CFB boilers

EMILE PROVENCE RED CAN GOLDENBERG AKRIMOTA TAMUIN

HUCHET HILLS
1991 1996 2001 2002 1992 2003 2002

OUTPUT 125 250 250 160 115 125 130

MWe

Coal Coal ( 4%S ) Lignite Lignite Brown coal Lignite Petcoke

FUEL Coal slurry Pitch

THERMAL > 89 % > 94 % > 93 % > 92 % > 89 % > 83 % (*) > 92 %

EFF.

DeSOx > 90 % > 97 % > 95 % > 95 % > 95 % > 95 % > 90 %

NOx < 200 < 250 < 250 250 <200 215 <200
mg/Nm3

(*) HHV basis

03/27/2021 Gyanendra Sharma, NPTI Delhi

 Emissions achieved CFBs
in Relation to the Fuel Type
Fuel Type NOX SO2 Desulphurization
Efficiency
mg/m³stp, 6 % O2 mg/m³stp, 6 % O2 %
Anthracite & Anthracite tailings 70 220 80
Petcoke 100 200 97
Slurry 110 140 95
Bituminous Coal 80 200 95
Eastern US Bituminous Coal 60 100 97
High Moisture Lignite 140 200 90
High Sulphur Lignite 160 200 97
Biomass 100 - -

03/27/2021 Gyanendra Sharma, NPTI Delhi

058 180p
 Ash Screw Cooler

Ash from Furnace

1560 - 1650 °F
850 - 900 °C

Ash to Bottom Ash

Handling System
400 °F / 200 °C
(Typical)

03/27/2021 Gyanendra Sharma, NPTI Delhi

056 340p
 Ash Screw Cooler
Details

Holo-Flite Screw
Heat Exchanger

Trough Jacket

03/27/2021 Gyanendra Sharma, NPTI Delhi

056 341p
 Water Cooled Ash
Cooler
Return to furna ce Ash inle t duct from
furna ce bottom

Conve yor a sh
Fluidizing a ir
to a sh silo
03/27/2021 Gyanendra Sharma, NPTI Delhi
056 323p
 Split Loop Seal
from Cyclone
Coa l

to Furna ce

03/27/2021 Gyanendra Sharma, NPTI Delhi

056 232px
 Utility Boiler
Major Recent References:

Power Station Mladá Boleslav

2 x 50 MW
Energy Supply for VW-Skoda Factory

• Technology - CFB
• Fuel - Bituminous
Coal
• Capacity t/h 2 x 140
• Design Pressure bar 145
• Temperature °C 535
• Commissioning - 1998
• Country - Czech Republic
• Customer - SKO Energo
03/27/2021 Gyanendra Sharma, NPTI Delhi
012 188p
 Power Station Cao Ngan,
2 x 50 MW
Longitudinal Section

+ 5 3 .0 m

Live Steam
115 bar (design pressure)
538 °C
66 kg/s (237.6 t/h)
Feedwater
223 °C
Fuel
Vietnamese Lean Coal
Customer
VINACOAL, Vietnam

03/27/2021 Gyanendra Sharma, NPTI Delhi ± 0 .0 m

012 223p
 Utility Boiler
Major References:

Power Station Ledvice

110 MW
CFB Fired Boiler in Czech Republic

• Technology - CFB
• Fuel - Brown Coal
• Capacity t/h 350
• Design Pressure bar 135
• Temperature °C 545
• Commissioning - 2001
• Country - Czech
Republic
• Customer - CEZ a.s.
03/27/2021 Gyanendra Sharma, NPTI Delhi
012 183p
 Utility Boiler
Major References:

Power Station Emile Huchet

125 MW
CFB Fired Boiler in France

• Technology - CFB
• Fuel - Bituminous
Coal
• Capacity t/h 367
• Design Pressure bar 155
• Temperature °C 545/540
• Commissioning - 1990
• Country - France
• Customer - SODELIF
03/27/2021 Gyanendra Sharma, NPTI Delhi
012 185p
 Utility Boiler
Major References:

Power Station Goldenberg

125 MW
Extra large Furnace due to wet
(up to 60 % water) Brown Coal

• Technology - CFB
• Fuel - Lignite
• Capacity t/h 400
• Design Pressure bar 135
• Temperature °C 505
• Commissioning - 1992
• Country - Germany
• Customer - RWE
03/27/2021 Gyanendra Sharma, NPTI Delhi
012 187p
 Akrimota,
Boiler with CFB
2 x 125 MW
+ 50.0 m

Live Steam
138 bar
538 °C
405 t/h
Reheater Steam
36 bar
537 °C
375 t/h
Feedwater
247 °C
Fuel
High Sulphur
Lignite

03/27/2021 Gyanendra Sharma, NPTI Delhi

± 0.0 m
012 217pÄ
 Utility Boiler
Major References:

Power Station Tamuin

2 x 130 MW
CFB Fired Boilers in Mexico

• Technology - CFB
• Fuel - Petroleum Coke
• Capacity t/h 2 x 395
• Design Pressure bar 154
• Temperature °C 540/540
• Commissioning - 2002
• Country - Mexico
• Customer - SITHE-IPG

03/27/2021 Gyanendra Sharma, NPTI Delhi

012 184p
 Utility Boiler
Major References:

RF#1&#2
2 x 150 MW
CFB Fired Boilers in Taiwan

• Technology - CFB
• Fuel - Petroleum Coke
• Capacity t/h 2 x 500
• Design Pressure bar 149
• Temperature °C 541
• Commissioning - 2002
• Country - Taiwan
• Customer - FHI

03/27/2021 Gyanendra Sharma, NPTI Delhi

012 198p
 Utility Boiler
Major Recent References:

+ 5 6 .7 m
Power Station Çan
2 x 160 MW
First CFB Fired Boilers in Turkey

• Technology - CFB
• Fuel - Lignite
• Capacity t/h 2 x 462
• Design Pressure bar 199
• Temperature °C 543/542
• Commissioning - 2002
• Country - Turkey
• Customer - TEAS

03/27/2021 Gyanendra Sharma, NPTI Delhi

012 154p
 Utility Boiler
Major References:

Tonghae Thermal Power Plant

2 x 220 MW
Reheat CFB Boilers in
Republic of Korea

• Technology - CFB
• Fuel - Anthracite
• Capacity t/h 2 x 693
• Design Pressure bar 172
• Temperature °C 541/541
• Commissioning - 1998 and 1999
• Country - Republic of Korea
• Customer - Tonghae
03/27/2021 Gyanendra Sharma, NPTI Delhi
011 422p
 Utility Boiler
Major References:

Power Station Provence

250 MW
First 250 MW CFB Boilers in the world

• Technology - CFB
• Fuel - Bituminous Coal
• Capacity t/h 700
• Design Pressure bar 193
• Temperature °C 565/565
• Commissioning - 1995
• Country - France
• Customer - SOPROLIF

03/27/2021 Gyanendra Sharma, NPTI Delhi

011 424p
 Utility Boiler
Major References:

Power Station Red Hills

2 x 250 MW

• Technology - CFB
• Fuel - Lignite
• Capacity t/h 2 x 753
• Design Pressure bar 203
• Temperature °C 540/568
• Commissioning - 2001
• Country - USA
• Customer - Choctaw Generation

03/27/2021 Gyanendra Sharma, NPTI Delhi

011 459p
 Utility Boiler
Major References:

Power Station Guayama

2 x 250 MW
Reheat CFB Boilers in Puerto Rico

• Technology - CFB
• Fuel - Bituminous
Coal
• Capacity t/h 2 x 819
• Design Pressure bar 207
• Temperature °C 540/540
• Commissioning - 2003
• Country - Puerto Rico
• Customer - AES
03/27/2021 Gyanendra Sharma, NPTI Delhi
011 423p
 250 MW CFB for
Indian
3 D Model
Lignite

03/27/2021 Gyanendra Sharma, NPTI Delhi

011 475p
 Fuels for
Circulating Fluidized
Beds
N CV Wa te r co nte nt Ash co nte nt Sulph ur
MJ/ kg We ig ht % a .r. We ig h t % a .r. % ma f
Anthra cite 16 8 37
Bituminous coa l 19 - 29 7 - 24 3 - 25
Lignite 12 - 18 12 - 4 2 12 - 2 6 5 .5 - 1 2
Brown coa l 8 - 12 35 - 5 8 1 - 40 1 - 13
Spe cia l fue ls:
Pe tcoke < 31 .0 < 5 < 1 < 7
Wood chips 12 36 2
Coa l slurry 1 0 .5 33 30
Pa pe r sludge 2.4 62 15
Se wa ge sludge 0.6 73 15
Ba rk 9 - 16 15 - 5 0 1 - 3 (20 )

03/27/2021 Gyanendra Sharma, NPTI Delhi

056 295p
 Reference Summary
• Fuels
Coal and lignite
Water content up to 60 %
Ash content up to 40 %
Sulphur content up to 13 % maf
various opportunity fuels
(coal, slurry, sewage sludge, petcoke, bark, ...)
• Water/Steam side
Natural circulation
Assisted circulation
Once-through (engineering study)
With/without reheat up to 560 °C
• Capacity
From 70 MWth up to 250 MWel
600 MWel under investigation
03/27/2021 Gyanendra Sharma, NPTI Delhi
141 269p
 Advantages of CFB
for High Sulphur Lignite
• Desulphurization of > 97 % achievable

• Reduced slagging tendency in the furnace

– No slagging due to pyrite of other sulphur components
– Reduced fouling in the backpass due to low
temperature
and even temperature profile

• Higher boiler efficiency

– Marginal SO3 in flue gas due to SO3 capture by
limestone
03/27/2021 Gyanendra Sharma, NPTI Delhi
056 374p – Therefore, flue gas exit temperature of 140 °C or less
 Lignite
Conclusion
Fired CFB Plants
• Sulphur content of 14 % (daf) commercially utilized in CFB
• Desulphurization of > 97 % achievable
• Special attention must be given to cyclone performance
• Equal fuel / air / limestone feeding into the furnace must be
ensured under all operating conditions
• Intensive testing is highly recommended:
– mine operation
– coal analysis with emphasis on type of sulphur
– available limestone sources and limestone reactivity
– combustion tests give valuable results
03/27/2021 Gyanendra Sharma, NPTI Delhi
056 377p
 Summary
• CFB technology is well developed today
More than 300 CFB plants are operating or are under construction
Plants with 250 MW capacity are running since 1995

• CFB technology meets environmental requirements

NOX values less than 200 mg/m3 s.t.p. and desulphurization
efficiencies higher than 97 % could be achieved

• CFB techhnology is able to burn a wide range of fuels

Especially high sulphur and/or high ash or high water coals could be
utilized
03/27/2021 Gyanendra Sharma, NPTI Delhi
001 673p
03/27/2021 Gyanendra Sharma, NPTI Delhi