AGENDA

UPPC: preparative training May 17. 2005/JVI CONFIDENTIAL

BASICS MISCELLANNEOUS

• FLUIDIZATION • FUEL
• FLUID BED MODELS • INVENTORY OF FLUIDIZED BED MATERIAL
• COMBUSTION • TEMPERATURE CONTROL
• EROSION
• HEAT FLUX
• AIR DISTRIBUTION
• ADVANTAGES • HEAT TRANSFER SURFACES
• THE REAL THING • BED TEMPERATURE CONTROL BY INERTIA GAS
• APPROPRIATE BED TEMPERATURE
• SO2 REDUCTION
• NOx REDUCTION
• DYNAMICS
• START-UP
 CFB : BRIEF
UPPC: preparative training May 17. 2005/JVI CONFIDENTIAL

IN CIRCULATION FLUIDIZED BED THE COMBUSTION TAKES

PLACE IN DENSE SUSPENSION OF FLUIDIZED SOLIDS, WHICH
ARE CIRCULATED IN PROCESS

THESE SOLIDS, FLUIDIZED BY COMBUSTION AIR OF FLUE

GAS, CARRY OUT MAJOR HEAT TRANSFER IN FURNACE,
IMPROVE MIXING OF AIR AND FUEL AND ALSO CRUSH AND
GRIND THE FUEL PARTICLES. THE HEAT ACCUMULATED IN
SOLIDS MAKE COMBUSTION MORE STABLE, TOO

AS RESULT THE COMBUSTION IS STABLE, EASY TO

CONTROL, MAKES POSSIBLE COMBUSTION OF VERY
DIFFERENT FUELS, AND MINIMIZES THE EMISSIONS
 CFB : BASICS
UPPC: preparative training May 17. 2005/JVI CONFIDENTIAL

BASICS

• FLUIDIZATION
• COMBUSTION
 FLUIDIZATION REGIMES
UPPC: preparative training May 17. 2005/JVI CONFIDENTIAL
 Bed DP in Different Fluidization Regimes
UPPC: preparative training May 17. 2005/JVI CONFIDENTIAL
 Types of Fluidized Bed Boiler
UPPC: preparative training May 17. 2005/JVI CONFIDENTIAL

Bubbling Fluidized Bed Boiler

Ø Superficial velocities 2-3 m/s
Ø Distinct visible bed level
Ø Suitable for high moisture fuels (to keep gas velocities low)
Ø Low bed cooling capacity, not for high HV value, low volatile fuels

Circulating Fluidized Bed Boiler

Ø Superficial velocities 4.5-5 m/s
Ø No distinct visible bed level; decreasing bed density with height
Ø Long particle residence times of a few minutes in the hot loop
Ø Particle separator and loop seal recirculates material in hot loop
Ø Good for large range of fuels, also high HV and low volatile fuels
 Development of CFB
UPPC: preparative training May 17. 2005/JVI CONFIDENTIAL

1979 1988 1992 - 1996 -

Water/steam Water/steam cooled

cooled cyclone integrated separator
 CFB CHARACTERISTICS

UPPC: preparative training May 17. 2005/JVI CONFIDENTIAL

Flue gas
800-900°C

FEATURE BENEFIT

• Low furnace • Low NOx 800-900°C

temperatures • Low SO2
4.5-5.0 m/s
• Hot circulating solids • Fuel flexibility
• Handles low grade
fuels
• Simple feed systems
Limestone <1mm
• Long solid residence • Good fuel burnout
time Coal <10mm
• Good sorbent
utilization Biomass <50mm

Air
 Steam Outlet
Steam
Water FOSTER WHEELER CFB
Steam Drum
FLOW CHART
UPPC: preparative training May 17. 2005/JVI CONFIDENTIAL

Downcomer
Water
Wall

Separator Economizer
Fuel Limestone

Feed Water Inlet

Air Dust Collector
heater

Combustion
Chamber

Fly Ash

Induced Draft
Secondary Air Fan Fan
compact.eng/comflow.ds4/0801/tap Bottom
Ash To Ash Silos Primary Air Fan
 CFB COMBUSTION BASICS
UPPC: preparative training May 17. 2005/JVI CONFIDENTIAL

CARBON IN FUEL + OXYGEN + TEMPERATURE

= COMBUSTION

RELEASE ENERGY, HEAT

ØCombustibles in in fuel as fixed carbon and volatile matters
ØPartly Gas-solid reaction (mixing/grinding critical)
ØPartly gas-gas reaction (volatile matters), air supply staggering
critical
ØReaction kinetics important (temperature and time influence rate
of reaction)
Ø Released temperature need to be controllable
Ø Air/fuel ratio need to be controllable
 NUTSHELL: THE OPERATION PRINCIPLE
UPPC: preparative training May 17. 2005/JVI CONFIDENTIAL

IN CFB...
THE FUEL IS APPLIED TO LOWEST AND DENSEST PART OF FLUID BED

APPLYING PRIMARY AIR TO HOT BED IGNITE THE FUEL AND BURN PART OF FUEL :
FIRST THE VOLATILE MATTERS,WITHIN SOME MORE TIME THE FIXED
COMBUSTIBLES.

THE SECONDARY AIR IN UPPER ELEVATIONS COMPLETE THE COMBUSTION, ALSO

IGNITES THE VOLATILE MATTERS THAT ESCAPED IGNITION IN LOWER PART
THE HEAT FROM COMBUSTION IS TRANSFERRED BY GAS AND PARTICLES TO HEAT
ABSORBING (COOLING) SURFACES

IN CFB, THE FLUID BED PARTICLES, FINES, FORM THE MOST EFFICIENT HEAT
TRANSFER, RESULTING VERY LOW AND EVEN TEMPERATURES OF CFB FURNACE

THEREFORE: HIGHER THE VELOCITY AND DENSITY OF FLUID BED PARTICLES,

HIGHER THE HEAT TRANSFER RATE AND BETTER THE COOLING
 COMBUSTION BASICS: THREE T’s
UPPC: preparative training May 17. 2005/JVI CONFIDENTIAL

Three T’s
Ø Time (residence times)
Ø Temperature
Ø Turbulence (mixing)
 COMBUSTION BASICS
UPPC: preparative training May 17. 2005/JVI CONFIDENTIAL

RESIDENSE TIME
In CFB boilers
Ø Coal particle travels from furnace – separator – loop seal –
furnace until coal size drops below cyclone cut-off size.
Residence times on the order of minutes.
Ø Larger sized coal particles will still burn completely because of
long residence times.
 COMBUSTION BASICS
UPPC: preparative training May 17. 2005/JVI CONFIDENTIAL

TEMPERATURE FACTOR
In CFB boilers
Ø Bed temperature below 982C. No risk of thermal NOx, hence
overall NOx emissions low.
Ø In-situ sulfur capture possible (optimum temp: 850-900C); does
not need back-end scrubbers unlike in a PC boiler.
Ø Time (residence) and turbulence are superior, hence despite
lower temperatures combustion efficiency is good.
 COMBUSTION BASICS
UPPC: preparative training May 17. 2005/JVI CONFIDENTIAL

TURBULENCE FACTOR
Turbulence: Combustion of solid fuel is a gas-solid reaction. If
O2 does not contact the solid fuel particle, there can be no
reaction. High degree of mixing in the bed (turbulence) ensures
enough air in contact with fuel particle, hence ensures better
combustion. In addition, it helps to grind the oxidized surface of
fuel particle, and so uncovers new carbon for reaction

Ø Fluidized bed technology is characterized by excellent mixing

between air and solid particles that constitute the bed.
Ø In CFB boiler air is admitted over the entire grid with additional
air from wall nozzles. Mixing is excellent.
Ø Good mixing ensures complete combustion, low CO emissions.
 CFB HEAT FLUX ON DIFFERENT LOAD
UPPC: preparative training May 17. 2005/JVI CONFIDENTIAL
 CFB HEAT FLUX ON DIFFERENT LOAD
UPPC: preparative training May 17. 2005/JVI CONFIDENTIAL
 CFB HEAT FLUX ON DIFFERENT LOAD
UPPC: preparative training May 17. 2005/JVI CONFIDENTIAL
 LOAD CHANGES
UPPC: preparative training May 17. 2005/JVI CONFIDENTIAL

PROJECT X SIMULATIONS : load change 40%à 100% , 10% step changes, volumetric feed
220.00

200.00

180.00

160.00
MASS FLOW RATE (kg/s)

140.00

120.00

100.00

80.00

60.00

40.00

20.00

0.00
0 400 800 1200 1600 2000 2400 2800 3200 3600 4000 4400 4800 5200 5600 6000 6400 6800 7200 7600 8000 8400 8800 9200 9600
TIME (S)

FUEL FEED PRIMARY AIR FLOW SECONDARY AIR FLOW MAIN STEAM FLOW
 SUMMARY OF CFB ADVANTAGES I
UPPC: preparative training May 17. 2005/JVI CONFIDENTIAL

Ø Can burn a wide range of low grade fuels, due to the large heat
capacity and mixing of the bed
Ø High combustion efficiency, due to turbulent mixing and long
residence time in the circulating bed.
Ø Low SO2 emissions, due to ease of sulfur retention with limestone at
ideal temperatures
Ø Low NOx emissions, due to low operating bed temperature (less than
920 C) and staged combustion
Ø Low CO and CxHy emissions, due to turbulent condition and long
residence time and mixing in the separator
 SUMMARY OF CFB ADVANTAGES II
UPPC: preparative training May 17. 2005/JVI CONFIDENTIAL

Ø Stable operating conditions and boiler response due to the high heat
transfer from the circulating material
Ø Good turn down rates due to heat transfer being approximately
proportional to load. No need to slump a section of the bed at low
loads
Ø No need for in-bed tubes which are subject to erosion
Ø Fewer fuel feed points due to better mixing in the bed compared to
bubbling beds
Ø Quicker hot restarts of the boiler due to the large reserve of stored
heat in the bed material
 SUMMARY OF CFB ADVANTAGES III
UPPC: preparative training May 17. 2005/JVI CONFIDENTIAL

Ø Lower operating temperature mean fewer gaseous pollutants and

less equipment needed to clean up the combustion process while
burning a variety of fuels
Ø The ratios between gas velocity and minimum solid’s entrainment
velocity allow turndown ratios as high as four to one (4:1).
Ø Operation over a wide range of boiler loads is possible without
starting and stopping burners and auxiliary equipment.
 THE REAL THING...
UPPC: preparative training May 17. 2005/JVI CONFIDENTIAL
 MISCELLANEOUS
UPPC: preparative training May 17. 2005/JVI CONFIDENTIAL

FUEL
INVENTORY OF FLUIDIZED BED MATERIAL
TEMPERATURE CONTROL
EROSION
AIR DISTRIBUTION
HEAT TRANSFER SURFACES
BED TEMPERATURE CONTROL BY INERTIA GAS
APPROPRIATE BED TEMPERATURE
SO2 REDUCTION
NOx REDUCTION
DYNAMICS
START -UP
LIMESTONE
 FUEL : PROPERTIES
UPPC: preparative training May 17. 2005/JVI CONFIDENTIAL

• HEAT VALUE:
• High HV increase the heat input to bed (usually related to lower cooling effect by moisture and combustion air
demand)
à High HV means higher temperatures

• VOLATILE MATTERS
• gaseous portion of combustibles in fuel, fast reacting and burning evaporating gases. This portion evaporates from
fuel, ignites
and burns first, usually emitting heat on higher elevation than lowest bed.
à high volatile means typically lower bed temperatures, combustion takes place on upper elevations
à higher volatile content typically mans lower primary/secondary ratio

• FIXED CARBON
• The slowest burning portion of combustibles, usually burns when the coal particles grind and cruch in bed.
à Higher fixed carbon means typically higher bed temperatures

• ASH CONTENT:
• Higher ash content gives more heat transferring fine material in furnace
à (very far simplified...) higher ash means lower temperatures (note: Limestone behaves like ash in furnace)

• MOISTURE:
• Higher moisture absorbs energy from fue when evaporating, atomize the fuel to more volatile, and increase the heat
transferring gas volume
à high moisture means lower bed temperatures
à higher moisture means higher flue gas velocities
 FUEL :PROPERTIES
UPPC: preparative training May 17. 2005/JVI CONFIDENTIAL
 FUEL: SIZE DISTRIBUTION
UPPC: preparative training May 17. 2005/JVI CONFIDENTIAL

TOO SMALL SIZE DISTRIBUTION:

A lot of surface for reaction, fast burning, short residence in furnace, may
fly out of comburstor before completely burned

TOO LARGE SIZE

Less surface for reaction, matters may not vaporize properly and leave
unburned carbon residue in ash, very large particles may come out of
bottom ash system before completely burned

TYPICALLY, LESS REACTIVE (LOW VOLATILE) FUELS NEED TO BE

CRUSHED TO SMALLER SIZE TO INCREASE THE SPECIFIC REACTIVE
SURFACE
 INVENTORY OF FLUIDIZED BED MATERIAL

UPPC: preparative training May 17. 2005/JVI CONFIDENTIAL

THE FLUID BED MATERIAL, FINES, PLAYS MAIN ROLE IN

TRANSFERRING THE HEAT FROM BED TO COOLING SURFACES.

MORE FINE BED MATERIAL, LESS IMPACT TO TUBES, LOWER THE

GAS VELOCITY NEEDED TO TRANSFER THE HEAT:
à LESS EROSION

FUEL ASH FORM MAIN SOURCE FOR BED MATERIAL.

IF ASH IS INSUFFICIENT TO FORM BED, OR IT IS IMPROPER QUALITY,
ADDITIONAL MAKE-UP BED MATERIAL IS NEEDED, CONSEQUENTLY.

THE MOST COMMON MAKE-UP BED MATERIALS ARE SAND AND

LIMESTONE
 INVENTORY OF FLUIDIZED BED MATERIAL

UPPC: preparative training May 17. 2005/JVI CONFIDENTIAL

SAND:
• Typically hard, abrasive, resulting erosion
• High SIlica sands are the most abrasive
• Natural sand has quite long lifetime in turbulent fluid bed conditions, low
consumption

LIMESTONE
• Typically soft, less abrasive than sand, less erosion than sand
• Mainly user for sulfur detention in furnace
• Reactions and softness cause that limestone breaks down in furnace,
à shorter lifetime as bed material, consumtion higher than sand

Note: to save limestone the fly ash is sometimes recirculated to furnace

 INVENTORY OF FLUIDIZED BED MATERIAL

UPPC: preparative training May 17. 2005/JVI CONFIDENTIAL

THE FEED RATE OF MAKE-UP MATERIAL IS DETERMINED BY

COMBINATION OF FOLLOWING INDICATORS:

• Coarseness of bed material, as indicated by bottom ash coarseness

• Bed pressure (evenness of readings and bed thickness)
• Bed temperatures
• Signs of agglomeration in bed material (clusters in bottom ash)

IN PRACTICE, THE APPROPRIATE MAKE-UP FEED RATE WILL BE

CHECKED AND DETERMINED DURING THE COMMISSIONING, TO BE
CONTINUED DURING THE NORMAL OPERATION
 BED MATERIAL SUMMARY
UPPC: preparative training May 17. 2005/JVI CONFIDENTIAL

IN CFB, THE FINE BED MATERIAL IS THE MAIN PARTY IN TRANSFER

OF HEAT FROM BED TO HEAT ABSORBING SURFACES
THE BED MATERIAL IS FORMED BY INERTIA PARTICLES OF
FUEL ASH, ADD-ON LIMESTONE AND MAKE-UP SAND
INSUFFICIENT AND TOO LARGE SIZE BED MATERIAL INVENTORY
INCREASE THE BED TEMPERATURES AND EROSION
HIGH SILICA SAND AND SOME ASH TYPES ARE VERY ABRASIVE AND
CAUSE EROSION, WHEREAS LIMESTONE IS SOFT AND GENTLE FOR TUBES
SAND LIFETIME IN FURNACE IS MULTIPLE TO LIMESTONE AND ASH,
à CONSEQUENTLY SAND CONSUMPTION AS MAKE-UP MATERIAL IS LOW
LIMESTONE BREAKS-DOWN IN FURNACE:
à LIMESTONE CONSUMTION AS BED MATERIAL IS HIGH.
THE LIMESTONE AND SAND FEED RATES WILL BE DEFINED DURING
THE COMMISSIONING
 TEMPERATURE CONTROL
UPPC: preparative training May 17. 2005/JVI CONFIDENTIAL

• HIGHER THE VELOCITY OF MEDIA (= gas and particles), MORE HEAT CAN BE
TRANSFERRED TO ABSORBING SURFACES

à NOTE: EXCESSIVE VELOCITY ÌNCREASE EROSION FAST

• HIGHER THE SUSPENSION (DENSITY) OF FINES, MORE HEAT CAN BE TRANSFERRED

TO ABSORBING SURFACES

THEREFORE, PRIMARY AIR IS MORE EFFICIENT BEDCOOLERTHAN SECONDARY AIR:

COMING THROUGH THE BED, MORE PRIMARY AIR EFFECTIVELY CARRIES MORE
PARTICLES TO HIGHER ELEVATION

à NOTE: EXCESSIVE PRIMARY AIR CARRY LARGER PARTICLES WITH

LARGER VELOCITY INCREASING EROSION FAST
 EROSION
UPPC: preparative training May 17. 2005/JVI CONFIDENTIAL

Erosion rate

150
140
130
120
110
100
90
80
70
60 FW limit

50
40
30
20
10
0
4.5 4.7 4.8 5.0 5.2 5.4 5.6 5.8 6.0 6.2 6.4

Furnace velocity
 AIR DISTRIBUTION
UPPC: preparative training May 17. 2005/JVI CONFIDENTIAL

CONCLUSIONS:
- SUFFICIENT PRIMARY AIR TO IGNITE THE FUEL AND TO
CONTROL THE BED TEMPERATURES
àAVOID EXCESSIVE PRIMARY AIR
- increases erosion
- increase NOx emission
- increase power consumption
- THE SECONDARY AIR TO COMPLETE THE COMBUSTION
àAVOID EXCESSIVE TOTAL AIR
- increases losses
- increase velocity and erosion
- increase power consumption
THE SECONDARY AIR TO COMPLETE THE COMBUSTION
 HEAT ABSORBING SURFACES
UPPC: preparative training May 17. 2005/JVI CONFIDENTIAL

• THE HEAT FROM THE FUEL/BED IS TRANSFERRED TO WATER OR STEAM COOLED

HEAT ABSORBERS (COOLING SURFACES)

• EVAPORATIVE SURFACES ARE BETTER COOLERS THAN SUPERHEATERS

• THE HEAT ABSORBER LOCATED IN FURNACE ARE THE MOST EFFICIENT TO

CONTROL BED TEMPERATURES

• THE COOLING SURFACES NEED TO BE DIMENSIONED SO, THAT SUFFICIENT

COOLING IS PROVIDED WITH REASONABLE FURNACE VELOCITIES

• THE HEAT ABSORBERS THAT COOL THE FURNACE/BED

à WATER WALLS
à WINGWALLS
à OMEGA PANELS
à COOLED SEPARATOR, RETÙRN
à INTREX design
 BED TEMPERATUR CONTROL BY INERTIA GAS
UPPC: preparative training May 17. 2005/JVI CONFIDENTIAL

BY REPLACING PART OF PRIMARY AIR BY INERTIA (LOW OXYGEN) GAS

TYPICALLY BY RECIRCULATING FLUE GAS AND INTRODUCING IT TO BED

COOLS THE BED BY TWO DIFFERENT WAYS

1) FLUIDIZE THE BED AND TRANSFER HEAT SIMILARLY TO PRIMARY AIR

à TRANSFER HEAT BY MOVING THE PARTICLES OF BED REGION
à HIGHER VELOCITY, HIGHER HEAT TRANSFER RATE

2) REPLACES PART OF COMBUSTION AIR IN BED REGION

à LESS OXYGEN TO REACT WITH FUEL
à LESS COMBUSTION, LESS HEAT IN BED REGION

AFTER REPLACING PRIMARY AIR WITH INERTIA GAS, THE COMBUSTION

MUST BE COMPLETED ON HIGHER ELEVATIONS BY INCREASING
SECONDARY AIR, CONSEQUENTLY (THE AIR DEMAND NEED TO BE
FULLFILLED)
 BED TEMPERATURE CONTROL BY INERTIA GAS
UPPC: preparative training May 17. 2005/JVI CONFIDENTIAL

RECIRCULATION GAS’s WDOUBLE WAYW TO CONTROL THE BED

TEMPERATURES MAKE RECIRCULATING GAS MORE EFFICIENT BED
TEMPERATURE CONTROLLER THAN PRIMARY AIR

CONSEQUENTLY, LESS RECIRCULATION GAS THAN PRIMARY AIR IS

NEEDED TO COOL THE BED TEMPERATURES

à DECREASE THE BED REGION VELOCITIES WHEN USED AS

ALTERNATIVE FOR USING EXCESS AIR (TO CONTROL THE
TEMPERATURES).

WRONGLY USED JUST WORSEN COMBUSTION AND INCREASE

VELOCITIES AND THUS EROSION, TOO
 APPROPRIATE OPERATION BED TEMPERATURE

UPPC: preparative training May 17. 2005/JVI CONFIDENTIAL

THE TYPICAL BED TEMPERATURES FOR DIFFERENT FUELS

- biomass :……………………… ..750 - 850 ºC
- low hv coal, peat, lignite : ……..800 - 950 ºC
- Anthracite, Petcoke, bit Coal…..860 - 1000 ºC

THE FOLLOWING CRITERIA DETERMINE THE CONTROL TEMPERATURES

- fuel combustion properties (HV, fixed carbon/volatiles etc)
- chemical properties i.e. risk of agglomeration
- fuel combustion properties, i.e. what temperature is needed for complete
burning
- emission limits, i.e sulphur capture and NOx
- furnace velocities
- material temperatures (applicaple in few rare cases)
 SO2 REDUCTION
UPPC: preparative training May 17. 2005/JVI CONFIDENTIAL

SULFUR CAPTURE

In-situ sulfur capture in the furnace, hot loop.

Two Step Reactions -

CALCINATION: CaCO3 + Heat = CaO + CO2 (needs heat)
SULFATION: CaO + ½O2 + SO2 = CaSO4 (gypsum)

Optimum Temperature: 843 – 900 C. Reaction stops above 950C.

90% sulfur can be captured in the optimum bed temperature range.
 SO2 REDUCTION
UPPC: preparative training May 17. 2005/JVI CONFIDENTIAL

Bed Composition
Limestone products are predominant in the CFB bed.
90% is reacted limestone, 2-3% is fuel
2-3% is unreacted limestone, 2-3% is ash

Sulfur Content
During calcination, limestone is weak, easily crumbles (loss by elutriation)
Fuel-S >2.5%, enough SO2 production à sulfation occurs rapidly.
This strengthens the limestone.
If Fuel-S is low, more limestone is needed for good SO2 capture.
 SO2 REDUCTION
UPPC: preparative training May 17. 2005/JVI CONFIDENTIAL
Limestone size distribution
120
Percent passing

100

80

60

40

20

10 100 1000

Size in microns
 SO2 REDUCTION
UPPC: preparative training May 17. 2005/JVI CONFIDENTIAL
 NO REDUCTION
UPPC: preparative training May 17. 2005/JVI CONFIDENTIAL

NOx Production
Ø Only fuel bound nitrogen is converted to NOx.
Ø Production of NOx is temperature dependent, higher the temperature higher
the NOx
Ø No thermal NOx at the low bed operating temperatures.

NOx Reduction
Air Staging Principle:
Ø Provide insufficient air in the lower bed to limit heat release
Ø Complete combustion by adding air through lower PA nozzles and SA
nozzles
Ø OPTIMIZE THE AIR DISTRIBUTION
 DYNAMICS
UPPC: preparative training May 17. 2005/JVI CONFIDENTIAL

PROJECT X SIMULATIONS : Load change 40 % -> 100 %, +4 %/min (MCR), volumetric feed
220.0
4 %/min (MCR)

200.0

180.0

160.0
MASS FLOW RATE (kg/s)

140.0

120.0

100.0

80.0

60.0

40.0

20.0

0.0
0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000 3200 3400 3600 3800 4000
TIME (S)

FUEL FEED PRIMARY AIR FLOW SECONDARY AIR FLOW MAIN STEAM FLOW
 DYNAMICS
UPPC: preparative training May 17. 2005/JVI CONFIDENTIAL

PROJECT X SIMULATIONS : load change 40%à 100% , 10% step changes, volumetric feed
220.00

200.00

180.00

160.00
MASS FLOW RATE (kg/s)

140.00

120.00

100.00

80.00

60.00

40.00

20.00

0.00
0 400 800 1200 1600 2000 2400 2800 3200 3600 4000 4400 4800 5200 5600 6000 6400 6800 7200 7600 8000 8400 8800 9200 9600
TIME (S)

FUEL FEED PRIMARY AIR FLOW SECONDARY AIR FLOW MAIN STEAM FLOW
 DYNAMICS
UPPC: preparative training May 17. 2005/JVI CONFIDENTIAL
PROJECT X SIMULATIONS : Ramp Load Change load decrease 100 %->40%,volumetric feed
220 181

200 179
Mass flow rate (kg/s)

180 HP by-pass quick opening 177

Pressure (bar)
160 175

140 173

120 171

100 169

80 167

60 165
0 500 1000 1500 2000 2500 3000 3500 4000
Time (s)
Main steam flow Main steam pressure
 START-UP
UPPC: preparative training May 17. 2005/JVI CONFIDENTIAL
Project XX
Cold start-up - Bed T and Fuel Input (MW)
1000 Bed temperature C 300
Open boiler
Burners MW main steam Turbine starts
900 Solid fuel MW stop valve's Turbine 100% load
by pass valve Turbine
Fuel total MW 250
synchro
800

700 Aux. steam Start boiler -

ready vacuum ready 200
Start of Start by-pass

Fuel Power (MW)

600
Temperature (C)

vacuum operation
pumps
500 Start boiler 150
filling

400

100
300

200
50

100

0 0
-2:00 -1:00 00:00 01:00 02:00 03:00 04:00 05:00 06:00 07:00 08:00 09:00 10:00 11:00
Time (hh:mm)
 COMMISSIONING
UPPC: preparative training May 17. 2005/JVI CONFIDENTIAL
ID Task Name
Oct Nov Dec Jan Feb
26/09 03/10 10/10 17/1024/10 31/1007/11 14/11 21/1128/11 05/1212/12 19/1226/12 02/0109/01 16/0123/0130/01 06/02 13/02
5 DCS ready for Operation
6 Cold Testing
7 Loop checks + calibration for first fire
8 Loop checks + calibration for solid fuel
9 Furnace ready for air tests (Refract.& scaff removed, sealed)
10 ID fan test run
11 PA + SA fan test runs
12 HP Blowers + recirc gas fan test runs
13 Air&Gas tests (Flow test, Grid dp and ESP gas distribution test)
14 Purge Checks + BPS checks
15 Burner checks (BMS)
16 Oil Test Ignition
17 Purge Sequence Checks
18 Boiler seal-off for firing
19 Boiler safety review and walk-down for hot commissioning
20 ESP ready for oil fire
21 Oil Firing
22 Acid cleaning + restore
23 Hydro test
24 Re-start and first phase of refractory cure
25 Magnetite film formation + cure
26 Fill make-up sand in furnace
27 Steam Blow-out
28 Restoration
29 Test safety valves and protections
30 First Coal Fire
31 Initial Coal firing, protections + final cure
32 Initial test of sludge feeding system with medium
33 Steam to T/G
34 Ramp test + controls in service + initial tuning for operation
35 Start Sludge Firing
36 Sludge Ramp test + controls in service + initial tuning for Operation
37 Test run + Process&controls fine tuning
38 Shut down before Performance Test
39 Performance Test
40 Operation Test Acceptance
41 BOILER COMMISSIONING
334 CONTROLS COMMISSIONING
 COMMISSIONING
UPPC: preparative training May 17. 2005/JVI CONFIDENTIAL

PRECOMMISSIONING
• checking the readiness of installation and systems for testing
• loop check
• checking the readiness of programs in DCS and PLC
• checking the readiness and of interlocks and protections in DCS
• alignments of rotating machines and ducting
• calibration
• lubrication
• cold adjusting of moving parts, like dampers and actuators, checking that
equipment can move free
• check the spring hangers and supports, and verify the space for thermal
movements
• motor turning, ”bumb-test”
 COMMISSIONING
UPPC: preparative training May 17. 2005/JVI CONFIDENTIAL

PRECOMMISSIONING
• checking the readiness of installation and systems for testing
• loop check
• checking the readiness of programs in DCS and PLC
• checking the readiness and of interlocks and protections in DCS
• alignments of rotating machines and ducting
• calibration
• lubrication
• cold adjusting of moving parts, like dampers and actuators, checking that
equipment can move free
• check the spring hangers and supports, and verify the space for thermal
movements
• motor turning, ”bumb-test”
 COMMISSIONING
UPPC: preparative training May 17. 2005/JVI CONFIDENTIAL

TO START-UP, TEST AND OPTIMIZE AND DOCUMENT THE

EQUIPMENT AND SYSTEMS SEPARATELY, AND FINALLY ALL
PROCESS TOGETHER AS ENTIRE SYSTEM.

TARGET IS SAFE, HIGHLY PERFORMING AND PRACTICAL RESULT

WHICH IS DOCUMENTED FOR FUTURE TROUBLESHOOTING,
IMPROVEMENTS AND MODIFICATIONS
 COMMISSIONING
UPPC: preparative training May 17. 2005/JVI CONFIDENTIAL

THE FIRST IGNITION

• ventilation and ignition
• oil firing adjustments for bed warm-up
• first step of refractory curing
• checking/adjusting the minimum air (primary air pressure/flow)
 COMMISSIONING
UPPC: preparative training May 17. 2005/JVI CONFIDENTIAL

SAFETY AND INTERLOCK TESTS

• following the requests by owner, local outhorities, insurer
• safety valve testing and setting
• primary tests of main interlock
• note: if any changes made to settings, conditions or logics of main
interlocks, that
need to be primarily tested and recorded.
 COMMISSIONING
UPPC: preparative training May 17. 2005/JVI CONFIDENTIAL

FIRST COAL IGNITION

• repeated ignition of coal to practice and to find the settings/procedure
• set minimum primary/secondary air for coal light-up
• monitor the settings for windbox flow and pressure
 COMMISSIONING
UPPC: preparative training May 17. 2005/JVI CONFIDENTIAL

UNIT LOAD-UP
• load profile min-max
• Repeating load step tests to determine appropriate air curves
• Bed cooling with recirculation gas fan
• Primary concentration on main fuel, coal
• Wingwall material temperatures tube outlets (leave IR point access in
outlet )
 COMMISSIONING
UPPC: preparative training May 17. 2005/JVI CONFIDENTIAL

BOILER TUNING ON LOAD

• Target to make full load
• First concentration on main fuel, coal (expected to be more difficult)
• Bed cooling, air distribution, optimized performance
• Sludge firing
 COMMISSIONING
UPPC: preparative training May 17. 2005/JVI CONFIDENTIAL

PROCESS TUNING
• Load as requested for optimizing
• Control loop tuning
• Combustion air tuning (air curves, prim/sec ratio etc)
• Bed temperature control tuning; different aspects of bed temperature control
à Limestone and sand feed rates and criteria (bottom ash, bed pressure,
temperature etc)
à Bed quality criteria (coarness) for normal operation
à Primary/ secondary air ratio (air curve) and coefficient to tune to ratio
à Recirculation gas controls
à O2 set points and control
à Bed temperature set point

• Confirm the appropriate bed inventory for operation (bed pressure)

• Confirm the settings for windbox pressure and primary air flow
• Set the limitations for biomass portion in control system
 COMMISSIONING
UPPC: preparative training May 17. 2005/JVI CONFIDENTIAL

SLUDGE BURNING TEST

• Fill up the silo and start feeding gradually
• Set the air curves for reject / biomass feed on different loads
• Bottom ash follow-up and removal
 COMMISSIONING
UPPC: preparative training May 17. 2005/JVI CONFIDENTIAL

PERFORMANCE TEST
• similar procedure to pre-performance test