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Circulating Fluidised Bed Combustion (CFBC) Boilers Powerful solutions for steam generation

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Works Pimpri, Pune - 411 018, India Telephone : (020) 2742 5461 - 64, Fax : (020) 2742 5350 E-mail : TKII@thyssenkruppindia.com Cherlapally, Hyderabad - 500 051, India Telephone : (040) 2726 3540 / 2726 3896 / 2726 3647 / 2726 2762 Fax : (040) 2726 3162, E-mail : tkii_hyd@vsnl.net Registered Office 154 C, Mittal Tower, 15th Floor, 210, Nariman Point, Mumbai : 400 021, India Telephone : (022) 2202 0064 / 6837, Fax : (022) 2204 4025 E-mail : tkii_mumbai@vsnl.net Branch Office Chennai Temple Tower, 5th Floor, Nandanam, 672, Anna Salai, Chennai - 600 035, India Telephone : (044) 2434 6993 / 2433 9482, Fax : (044) 2434 8198 E-mail : tkii_chennai@vsnl.net Kolkata 4 B, Park Plaza, 71 Park Street, Kolkata - 700 016, India Telephone : (033) 2217 2403 / 2461 1109, Fax : (033) 2226 5710 E-mail : tkii_kolkata@vsnl.net Lucknow B-8, Sector E, Aliganj, Lucknow - 226 024, India Telephone : (0522) 2334 251, Fax : (0522) 2334 250 E-mail : tkii_lucknow@sify.com New Delhi 407 A, Hemkunt Tower, 98, Nehru Place, New Delhi - 110 019, India Telephone : (011) 2644 9971 / 72 / 73, Fax : (011) 2646 8968 E-mail : tkiidelhi@eth.net

ThyssenKrupp Industries India Pvt. Ltd (An ISO 9001 : 2000 Company) Pimpri, Pune - 411 018, India Telephone : (020) 2742 5461 - 64, Fax : (020) 2742 5350 E-mail : TKII@thyssenkruppindia.com Website : www.thyssenkruppindia.com

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ThyssenKrupp Industries India

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Steam Generators with Circulating Fluidised Bed Combustion (CFBC) Technology

second pass, at a temperature O of around 400 C. It is recirculated into the combustion chamber via a siphon system which serves as a seal. The heated combustion air from airheater is passed through the air nozzles into the fluidised bed as primary air, and above the fluidised bed into the freeboard as secondary/tertiary air. Combustion takes place within an optimum temperature of O O 800 C to 950 C.

are burnt. This post-combustion releases approx. 40% of the total combustion heat and then is transferred to the flue gas or, by way of radiation to the cooled combustion chamber walls. The amply dimensioned freeboard height guarantees a mean residence time of flue gases of at least 4 seconds. The correspondingly long residence time of elutriated fuel particles has its decisive share in the high degree of combustion and desulphurization efficiency. The recirculated fly ash quantity is adjusted to maintain a temperature of the fluidised bed O of about 850 C. This quantity of fly ash recirculation suffices to ensure the burn-out of fines and the capture of sulphur in the freeboard at optimal consumption of limestone.

The flue gases are conducted to the chimney via an ESP and induced draught fan. The preparation of fuel is relatively simple. The fuel is crushed to a size of apprx. 8 mm. No grinding of coal is necessary. The fuel is fed into the fluidised bed together with recirculated fly ash. Limestone can be added to the fuel to capture sulphur, if required, to meet stringent SOx emission values.

1. Boiler drum 2. Airbox 3. Boiler under erection

ThyssenKrupp Industries India offers a wide range of worldclass Circulating Fluidised Bed Combustion Boilers. A modern concept in steam generators, these state-of-the-art systems are designed and manufactured for a wide range up to about 500 TPH. These boilers have multi-fuel firing capacity, high thermal efficiency, low emissions of SOx & NOx and can effectively utilise high ash coals, lignites, washery rejects, petcoke, etc.

The system
The fuel and the cold fly ash recirculated to the fluidised bed is well mixed with the hot bed material resulting in a uniform temperature distribution in the bed. This is achieved by a higher turbulence caused by introducing fluidising air in smaller bed dimensions. Unlike the Bubbling AFBC boilers the erosion prone submerged heating surfaces are dispensed with. The recirculated cold fly ash takes over the cooling of the fluidised bed. It is in the convection pass that the heat taken is transferred to the convectional heating surfaces. The boiler has a tower-type arrangement. The first boiler pass is formed by water-cooled, gas-tight

membrane tube walls. They are part of the evaporator system and are designed for natural circulation. The lower section of the first boiler pass consists of the combustion chamber with the fluidised bed and the freeboard above. The upper section is made up of a convection heating surfaces namely superheater, evaporator and part economiser. This first boiler pass is top supported allowing easy expansion downwards. The second boiler pass has remaining part of the economiser heating surface and the tubular airheater. The elutriated fly ash is separated from the flue gases in cyclone separators located between the boiler first and

The ash from the fluidiesd bed, the cyclone and the ESP is conveyed pneumatically to the main ash silo, keeping the plant clean of ash. The boiler is designed with fluidising velocities up to 4.5m/s, generating a high turbulence and resulting in a good mixing of hot bed material with fuel and recirculated fly ash. The height of the bed is kept constant by removal of the produced bed ash as a function of the differential pressure between the airbox and freeboard. In the freeboard (the upper part of the combustion chamber) the fine fuel particles with a size below 0.4 mm that have been elutriated from the fluidised bed and part of the volatile matter

Superior features of CFBC boiler - cold cyclone design

1. 2. 3. 4. 5. 6. 7. 8. High efficiency (even at part loads) - low operating cost. Wide fuel band - can burn coal, lignite, washery rejects, pet coke etc. Simple fuel preparation - no grinding required Low emission levels - due to staged combustion Quick start up - due to cold cyclone design Good load chasing ability - comparable to PF boilers Low erosion risk - no bed tubes Reduced maintenance - minimum refractory

Advantages of Cold Cyclone CFBC Boiler over Bubbling Bed Boiler

1. 2. Particulars Economic range Type Thermal Eff. (Coal) Carbon burn up Power consumption Fuel flexibility Fuel preparation Fuel fines <1mm Fuel Moisture Reliability Response Auto Controls Fluidising velocity Furnace Resi. Time Bed heat release Bed Temp. Bed Temp. Control Bed level control Emission (mg/Nm ) -NOx -SO Limestone requirement Desulferisation Limit Meets pollution Norm Quick & +ve start-up Ease of Operation Bubbling Bed <60 TPH 2-pass 83% 93% ~ 14 KW/MW (th) Limited range <8 mm <20% ~10-12% Low Poor Combustion control not possible 2-3 m/sec 2-3 sec. ~1.5 MW/m Falls at part loads In-bed tubes & bed partition Intermittent draining <600 ~300 More 85% No No Less CFBC (Cold Cyclone) 60-500TPH Tower 87% 98% ~ 18 KW/MW (th) Wide range <8 mm <50% ~16% Very High Very good Possible 4-5 m/sec 4-5 sec. ~5.0 MW/m Constant Ash recirc & staged combustion Intermittent draining <200 ~300 Less 95% Yes Yes More Advantage for CFBC (Cold Cyclone) Lesser floor space requirement Better efficiency due to ash recirculation and longer reaction time in large furnace.
Higher bed height of 1600mm vs. 1300mm.

Advantages of Cold Cyclone CFBC Boiler over Pulverised Fuel Boiler

1 2. 3. 4. Particulars Thermal Efficiency Power consumption Oil Firing Fuel preparation - Fuel Flexibility - Max. Ash + H O - Abrasive coals - High sulphur fuels Emission (mg/Nm ) - NOx - SO Start up time - Moving Equipment - Maintenance Pressure Part - Arrangement - Erosion Soot Blowers Space Ash Handling Explosion Risk Boiler Control Burner Controls Pulverised Fuel ~87% Higher due to grinding Start up & upto 50% load <75 micron Limited ~62% High Mill Wear & maintenance FGD Plant reqd. ~ 650 ~ 2600 ~ 5 hrs. with multiple burner Feeders, Mills High 2 Pass type Moderate Many & all over More Wet & Dry High Complicated Complicated CFBC (Cold Cyclone) ~87% Lower than PF Only start up <8 mm Wide range ~ 75% None CaCO dosing <200 ~300 3-4 hrs with 2 Hot Gas Gen. Only feeders Low Tower type Less None Less Dry None Very Simple Very Simple Advantage of CFBC (Cold Cyclone) Practically Same No milling equipment Big savings in oil as no oil required for part lod operation No grinding of fuel. Less power. Very poor fuels can be burnt like lignite & washery rejects Adequate precaution taken for pressure part In situ SO capture Low NOx due to low combustion temp. of about ~850 C Meet pollution low of future also Big saving in oil bill & over all plant operation cost No mills Maintenance friendly Lesser floor space requirement. No gas turns on tube banks so less wear No steam consumption or maintenance Compact layout System very simple, clean & automatic Safe & reliable operation Only 2 Hot Gas Generators

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Staged air, larger furnace volume, more residence time No monsoon problems of feeder jamming & coal pipes jamming No inbed tubes, No erosion problems Equal to PF Stepless turndown upto 30% achievable. Leads to more compact furnace. Much better part load efficiency Auto combustion control possible. No bed tube erosion Due to larger furnace & staged combustion Due to ash & Limestone recirculation

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Start-up using Hot Gas Generator Simpler systems, auto controls

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Blue chip references

Client & location Tata Chemicals Ltd. Mithapur, Gujarat Nava Bharat Ferro Alloys Paloncha, Andhra Pradesh Hindalco Industries Ltd., (Unit Birla Copper), Dahej, Gujarat Bihar Caustic & Chemicals Ltd., Garhwa Road, Jharkhand Hindalco Industries Ltd. (Unit Birla Copper), Dahej, Gujarat Indian Aluminium Co. Ltd. (INDAL) Hirakud, Power Orissa HEG Ltd. (Graphite Division) Mandideep Near Bhopal, M. P. Jaiprakash Associates Ltd. Rewa, MP No. of Boilers 1 2 1 1 2 6 1 1 Capacity (TPH) 200 151 151 135 150 155/165 140 170 Pressure (Bar) 112 91 67 65 95 90.2 66 87 565 530 500 485 535 515 485 515 Fuel Lignite Coal Lignite/Coal Coal Coal Coal Coal Coal/ Washery Rejects/ Pet Coke Application Cogeneration Captive Power Cogeneration Captive Power Captive Power Captive Power Captive Power Captive Power

System features and advantages

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Turnkey solutions Quality Assurance in steam generation

ThyssenKrupp Industries India is in the field of design, manufacture, supply, installation and commissioning of a wide range of Steam Generating Plants for various industrial applications. The boilers service the diverse needs of different industries with multi-fuel capability, efficiency and environment friendly steam generation capabilities. The boiler range covers water tube boilers up to 500 tph including
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Natural circulation Tower-type design and long residence time of fuel particles and flue gases. Low fluidising velocities of 4 to 5 Meters/Sec. High carbon combustion efficiency of around 99% due to ash recirculation. No in-bed heating surfaces. Multi-fuel firing capability Simple fuel preparation without grinding. Low auxiliary power consumption. Cold cyclones with low refractory, operating at around 400 C, result in short - up and shut down time. Low emission values. Low ash recirculation rates and low dust load in combustor, preventing erosion.

Stringent quality control measures have earned ThyssenKrupp Industries India the ISO 9001 Quality Management System certification and the 'S', 'U' and 'PP' certificates of authorisation from ASME. Quality Assurance involves everything - starting from the planning and designing of the product and ending with trouble-free plant performance in the hands of satisfied customers. And standing testimony to the quality in-built into every plant, system and equipment supplied by ThyssenKrupp Industries India are the many repeat orders.

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