CFB Boiler Design, Operation and Maintenance

By Pichai Chaibamrung

Content Day1
1. Introduction to CFB 2. Hydrodynamic of CFB 3. Combustion in CFB 4. Heat Transfer in CFB 5. Basic design of CFB 6. Operation 7. Maintenance 8. Basic Boiler Safety 9. Basic CFB control

Objective
To understand the typical arrangement in CFB To understand the basic hydrodynamic of CFB To understand the basic combustion in CFB To understand the basic heat transfer in CFB To understand basic design of CFB To understand theory of cyclone separator

Know Principle Solve Everything

1. Introduction to CFB
1.1 Development of CFB 1.2 Typical equipment of CFB 1.3 Advantage of CFB

1.1 Development of CFB

1921, Fritz Winkler, Germany, Coal Gasification 1938, Waren Lewis and Edwin Gilliland, USA, Fluid Catalytic Cracking, Fast Fluidized Bed 1960, Douglas Elliott, England, Coal Combustion, BFB 1960s, Ahlstrom Group, Finland, First commercial CFB boiler, 15 MWth, Peat

1.2 Typical Component of CFB Boiler

1.2 Typical Component of CFB Boiler

Wind box and grid nozzle
primary air is fed into wind box. Air is equally distributed on furnace cross section by passing through the grid nozzle. This will help mixing of air and fuel for completed combustion

1.2 Typical Component of CFB Boiler

Bottom ash drain coarse size of ash that is not take away from furnace by fluidizing air will be drain at bottom ash drain port locating on grid nozzle floor by gravity. bottom ash will be cooled and conveyed to silo by cooling conveyor.

1.2 Typical Component of CFB Boiler

HP Blower supply high pressure air to fluidize bed material in loop seal so that it can overflow to furnace

Rotameter

Supplying of HP blower to loop seal

1.2 Typical Component of CFB Boiler

Cyclone separator located after furnace exit and before convective part. use to provide circulation by trapping coarse particle back to the furnace Fluidized boiler without this would be BFB not CFB

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1.2 Typical Component of CFB Boiler

Evaporative or Superheat Wing Wall located on upper zone of furnace it can be both of evaporative or SH panel lower portion covered by erosion resistant materials

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1.2 Typical Component of CFB Boiler

Fuel Feeding system
solid fuel is fed into the lower zone of furnace through the screw conveyor cooling with combustion air. Number of feeding port depend on the size of boiler

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1.2 Typical Component of CFB Boiler

Refractory refractory is used to protect the pressure part from serious erosion zone such as lower bed, cyclone separator

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1.2 Typical Component of CFB Boiler

Solid recycle system (Loop seal) loop seal is located between dip leg of separator and furnace. Its design physical is similar to furnace which have air box and nozzle to distribute air. Distributed air from HP blower initiate fluidization. Solid behave like a fluid then over flow back to the furnace.

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1.2 Typical Component of CFB Boiler

Kick out kick out is referred to interface zone between the end of lower zone refractory and water tube. It is design to protect the erosion by by-passing the interface from falling down bed materials

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1.2 Typical Component of CFB Boiler

Lime stone and sand system lime stone is pneumatically feed or gravitational feed into the furnace slightly above fuel feed port. the objective is to reduce SOx emission. Sand is normally fed by gravitation from silo in order to maintain bed pressure. Its flow control by speed of rotary screw.

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1.2 Typical Arrangement of CFB Boiler

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1.3 Advantage of CFB Boiler

Fuel Flexibility

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1.3 Advantage of CFB Boiler

High Combustion Efficiency - Good solid mixing - Low unburned loss by cyclone, fly ash recirculation - Long combustion zone In situ sulfur removal Low nitrogen oxide emission

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2. Hydrodynamic in CFB
2.1 Regimes of Fluidization 2.2 Fast Fluidized Bed 2.3 Hydrodynamic Regimes in CFB 2.4 Hydrodynamic Structure of Fast Beds

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2.1 Regimes of Fluidization

Fluidization is defined as the operation through which fine solid are transformed into a fluid like state through contact with a gas or liquid.

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2.1 Regimes of Fluidization

Particle Classification
Distribution CFB1 100% 75% 50% 25% 100% <600 <250 <180 <130 Size (micron) CFB2 <1000 <550 <450 <250 >100 BFB <1680 <1190 <840 <590 >420

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2.1 Regimes of Fluidization

Particle Classification

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2.1 Regimes of Fluidization

Comparison of Principal Gas-Solid Contacting Processes

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2.1 Regimes of Fluidization

Packed Bed
The pressure drop per unit height of a packed beds of a uniformly size particles is correlated as (Ergun,1952)

Where U is gas flow rate per unit cross section of the bed called Superficial Gas Velocity

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2.1 Regimes of Fluidization

Bubbling Fluidization Beds Minimum fluidization velocity is velocity where the fluid drag is equal to a particles weight less its buoyancy.

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2.1 Regimes of Fluidization

Bubbling Fluidization Beds For B and D particle, the bubble is started when superficial gas is higher than minimum fluidization velocity But for group A particle the bubble is started when superficial velocity is higher than minimum bubbling velocity

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2.1 Regimes of Fluidization

Turbulent Beds when the superficial is continually increased through a bubbling fluidization bed, the bed start expanding, then the new regime called turbulent bed is started.

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2.1 Regimes of Fluidization

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2.1 Regimes of Fluidization

Terminal Velocity

Terminal velocity is the particle velocity when the forces acting on particle is equilibrium

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2.1 Regimes of Fluidization

Freeboard and Furnace Height
- considered for design heating-surface area - considered for design furnace height - to minimize unburned carbon in bubbling bed - the freeboard heights should be exceed or closed to the transport disengaging heights

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2.2 Fast Fluidization

Definition

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2.2 Fast Fluidization

Characteristics of Fast Beds
- non-uniform suspension of slender particle agglomerates or clusters moving up and down in a dilute - excellent mixing are major characteristic - low feed rate, particles are uniformly dispersed in gas stream - high feed rate, particles enter the wake of the other, fluid drag on the leading particle decrease, fall under the gravity until it drops on to trailing particle

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2.3 Hydrodynamic regimes in a CFB

Cyclone Separator : Swirl Flow Back Pass: Pneumatic Transport

Furnace Upper SA: Fast Fluidized Bed Lower Furnace below SA: Turbulent or bubbling fluidized bed

Return leg and lift leg : Pack bed and Bubbling Bed

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2.4 Hydrodynamic Structure of Fast Beds

Axial Voidage Profile
Secondary air is fed

Bed Density Profile of 135 MWe CFB Boiler (Zhang et al., 2005)

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2.4 Hydrodynamic Structure of Fast Beds

Velocity Profile in Fast Fluidized Bed

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2.4 Hydrodynamic Structure of Fast Beds

Velocity Profile in Fast Fluidized Bed

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2.4 Hydrodynamic Structure of Fast Beds

Particle Distribution Profile in Fast Fluidized Bed

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2.4 Hydrodynamic Structure of Fast Beds

Particle Distribution Profile in Fast Fluidized Bed

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2.4 Hydrodynamic Structure of Fast Beds

Particle Distribution Profile in Fast Fluidized Bed
Effect of SA injection on particle distribution by M.Koksal and F.Hamdullahpur (2004). The experimental CFB is pilot scale CFB. There are three orientations of SA injection; radial, tangential, and mixed

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2.4 Hydrodynamic Structure of Fast Beds

Particle Distribution Profile in Fast Fluidized Bed
Increasing SA to 40% does not significant on suspension density above SA injection point but the low zone is denser than low SA ratio Increasing solid circulation rate effect to both lower and upper zone of SA injection point which both zone is denser than low solid circulation rate

No SA, the suspension density is proportional l to solid circulation rate

With SA 20% of PA, the solid particle is hold up when compare to no SA

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2.4 Hydrodynamic Structure of Fast Beds

Effects of Circulation Rate on Voidage Profile

higher solid recirculation rate

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2.4 Hydrodynamic Structure of Fast Beds

Effects of Circulation Rate on Voidage Profile

Pressure drop across the L-valve is proportional to solid recirculation rate

higher solid recirculation rate

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2.4 Hydrodynamic Structure of Fast Beds

Effect of Particle Size on Suspension Density Profile - Fine particle - - > higher suspension density - Higher suspension density - - > higher heat transfer - Higher suspension density - - > lower bed temperature

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2.4 Hydrodynamic Structure of Fast Beds

Core-Annulus Model - the furnace may be spilt into two zones : core and annulus
core

Core - Velocity is above superficial velocity annulus - Solid move upward Annulus - Velocity is low to negative - Solids move downward
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2.4 Hydrodynamic Structure of Fast Beds

Core-Annulus Model

core

annulus

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2.4 Hydrodynamic Structure of Fast Beds

Core Annulus Model - the up-and-down movement solids in the core and annulus sets up an internal circulation - the uniform bed temperature is a direct result of internal circulation

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3. Combustion in CFB
3.1 Coal properties for CFB boiler 3.2 Stage of Combustion 3.3 Factor Affecting Combustion Efficiency 3.4 Combustion in CFB 3.5 Biomass Combustion

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3.1 Coal properties for CFB Boiler

Properties - coarse size coal shall be crushed by coal crusher - sizing is an importance parameter for CFB boiler improper size might result in combustion loss - normal size shall be < 8 mm

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3.2 Stage of Combustion

A particle of solid fuel is injected into an FB undergoes the following sequence of events:
- Heating and drying - Devolatilization and volatile combustion - Swelling and primary fragmentation (for some types of coal) - Combustion of char with secondary fragmentation and attrition

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3.2 Stages of Combustion

Heating and Drying - Combustible materials constitutes around 0.5-5.0% by weight of total solids in combustor - Rate of heating 100 C/sec 1000 C/sec - Heat transfer to a fuel particle (Halder 1989)

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3.2 Stages of Combustion

Devolatilization and volatile combustion
- first steady release 500-600 C - second release 800-1000C - slowest species is CO (Keairns et al., 1984) - 3 mm coal take 14 sec to devolatilze at 850 C (Basu and Fraser, 1991)

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3.2 Stages of Combustion

Char Combustion
2 step of char combustion 1. transportation of oxygen to carbon surface 2. Reaction of carbon with oxygen on the carbon surface 3 regimes of char combustion - Regime I: mass transfer is higher than kinetic rate - Regime II: mass transfer is comparable to kinetic rate - Regime III: mass transfer is very slow compared to kinetic rate

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3.2 Stage of Combustion

Communition Phenomena During Combustion
Volatile release in non-porous particle cause the high internal pressure result in break a coal particle into fragmentation Attrition, Fine particles from coarse particles through mechanical contract like abrasion with other particles

Volatile release cause the particle swell

Char burn under regime I which is mass transfer is higher than kinetic trasfer. The sudden collapse or other type of second fragmentation call percolative fragmentation occurs

Char burn under regime I, II, the pores increases in size weak bridge connection of carbon until it cant withstand the hydrodynamic force. It will fragment again call secondary fragmentation

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3.3 Factor Affecting Combustion Efficiency

Fuel Characteristics the lower ratio of FC/VM result in higher combustion efficiency (Makansi, 1990), (Yoshioka and Ikeda,1990), (Oka, 2004) but the improper mixing could result in lower combustion efficiency due to prompting escape of volatile gas from furnace.

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3.3 Factor Affecting Combustion Efficiency

Operating condition (Bed Temperature) - higher combustion temperature --- > high combustion Limit of Bed temp efficiency
-Sulfur capture -Bed melting -Water tube failure

High combustion temperature result in high oxidation reaction, then burn out time decrease. So the combustion efficiency increase.

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3.3 Factor Affecting Combustion Efficiency

Fuel Characteristic (Particle size)

-The effect of this particle size is not clear -Fine particle, low burn out time but the probability to be dispersed from cyclone the high -Coarse size, need long time to burn out. -Both increases and decreases are possible when particle size decrease

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3.3 Factor Affecting Combustion Efficiency

Operating condition (superficial velocity) - high fluidizing velocity decrease combustion efficiency because Increasing probability of small char particle be elutriated from circulation loop

- low fluidizing velocity cause defluidization, hot spot and sintering

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3.3 Factor Affecting Combustion Efficiency

Operating condition (excess air) - combustion efficiency improve which excess air < 20%
Combustion loss decrease significantly when excess air < 20%.

Excess air >20% less significant improve combustion efficiency.

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3.3 Factor Affecting Combustion Efficiency

Operating Condition
The highest loss of combustion result from elutriation of char particle from circulation loop. Especially, low reactive coal size smaller than 1 mm it can not achieve complete combustion efficiency with out fly ash recirculation system. However, the significant efficiency improve is in range 0.0-2.0 fly ash recirculation ratio.

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3.4 Combustion in CFB Boiler

Lower Zone Properties - This zone is fluidized by primary air constituting about 40-80% of total air. - This zone receives fresh coal from coal feeder and unburned coal from cyclone though return valve - Oxygen deficient zone, lined with refractory to protect corrosion - Denser than upper zone

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3.4 Combustion in CFB Boiler

Upper Zone Properties - Secondary is added at interface between lower and upper zone - Oxygen-rich zone - Most of char combustion occurs - Char particle could make many trips around the furnace before they are finally entrained out through the top of furnace

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3.4 Combustion in CFB Boiler

Cyclone Zone Properties - Normally, the combustion is small when compare to in furnace - Some boiler may experience the strong combustion in this zone which can be observe by rising temperature in the cyclone exit and loop seal

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3.5 Biomass Combustion

Fuel Characteristics
- high volatile content (60-80%) - high alkali content sintering, slagging, and fouling - high chlorine content corrosion

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3.5 Biomass Combustion

Agglomeration SiO2 melts at 1450 C Eutectic Mixture melts at 874 C

Sintering tendency of fuel is indicated by the following (Hulkkonen et al., 2003)

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3.5 Biomass Combustion

Options for Avoiding the Agglomeration Problem
- Use of additives - china clay, dolomite, kaolin soil - Preprocessing of fuels - water leaching - Use of alternative bed materials - dolomite, magnesite, and alumina - Reduction in bed temperature

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3.5 Biomass Combustion

Agglomeration

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3.5 Biomass Combustion

Fouling
- is sticky deposition of ash due to evaporation of alkali salt - result in low heat transfer to tube

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3.5 Biomass Combustion

Corrosion Potential in Biomass Firing - hot corrosion - chlorine reacts with alkali metal from low temperature melting alkali chlorides - reduce heat transfer and causing high temperature corrosion

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4. Heat Transfer in CFB

4.1 Gas to Particle Heat Transfer 4.2 Heat Transfer in CFB

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4.1 Gas to Particle Heat Transfer

Mechanism of Heat Transfer
In a CFB boiler, fine solid particles agglomerate and form clusters or stand in a continuum of generally up-flowing gas containing sparsely dispersed solids. The continuum is called the dispersed phase, while the agglomerates are called the cluster phase. The heat transfer to furnace wall occurs through conduction from particle clusters, convection from dispersed phase, and radiation from both phase.

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4.1 Heat Transfer in CFB Boiler

Effect of Suspension Density and particle size

Heat transfer coefficient is proportional to the square root of suspension density

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4.1 Heat Transfer in CFB Boiler

Effect of Fluidization Velocity

No effect from fluidization velocity when leave the suspension density constant

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4.1 Heat Transfer in CFB Boiler

Effect of Fluidization Velocity

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4.1 Heat Transfer in CFB Boiler

Effect of Fluidization Velocity

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4.1 Heat Transfer in CFB Boiler

Effect of Vertical Length of Heat Transfer Surface

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4.1 Heat Transfer in CFB Boiler

Effect of Bed Temperature

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4.1 Heat Transfer in CFB Boiler

Heat Flux on 300 MW CFB Boiler (Z. Man, et. al)

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4.1 Heat Transfer in CFB Boiler

Heat transfer to the walls of commercial-size

Low suspension density low heat transfer to the wall.

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4.1 Heat Transfer in CFB Boiler

Circumferential Distribution of Heat Transfer Coefficient

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5 Design of CFB Boiler

5.1 Design and Required Data 5.2 Combustion Calculation 5.3 Heat and Mass Balance 5.4 Furnace Design 5.5 Cyclone Separator

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5.1 Design and Required Data

The design and required data normally will be specify by owner or client. The basic design data and required data are;

Design Data : - Fuel ultimate analysis - Feed water quality Required Data : - Main steam properties - Flue gas emission

- Weather condition - Feed water properties

- Flue gas temperature - Boiler efficiency

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5.2 Combustion Calculation

Base on the design and required data the following data can be calculated in this stage : - Fuel flow rate - Combustion air flow rate - Fan capacity - Fuel and ash handling capacity - Sorbent flow rate

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5.3 Heat and Mass Balance

Main steam Heat input Radiation Heat output

Feed water Blow down

Flue gas

Moisture in fuel and sorbent Fuel and sorbent

Unburned in fly ash

Combustion air

Unburned in bottom ash

Moisture in combustion air 84

5.3 Heat and Mass Balance

Mass Balance
Mass input Mass output Solid Fluein gas Solid Flue gas

Make up bed material

Fuel and sorbent

Moisture in fuel and sorbent Fuel and sorbent Make up bed material bottom ash bottom ash

fly ash

fly ash

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5.4 Furnace Design

1. 2. 3.

The furnace design include: Furnace cross section Furnace height Furnace opening

1. Furnace cross section Criteria - moisture in fuel - ash in fuel - fluidization velocity - SA penetration - maintain fluidization in lower zone at part load

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5.4 Furnace Design

2. Furnace height Criteria - Heating surface - Residual time for sulfur capture 3. Furnace opening Criteria - Fuel feed ports - Sorbent feed ports - Bed drain ports - Furnace exit section

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5.5 Cyclone Separator

6.1 Theory 6.2 Critical size of particle

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5.5 Cyclone Separator

The centrifugal force on the particle entering the cyclone is

The drag force on the particle can be written as

Under steady state drag force = centrifugal force

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5.5 Cyclone Separator

Vr can be considered as index of cyclone efficiency, from above equation the cyclone efficiency will increase for :

- Higher entry velocity - Large size of solid - Higher density of particle - Small radius of cyclone - low value of viscosity of gas
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5.5 Cyclone Separator

The particle with a diameter larger than theoretical cutsize of cyclone will be collected or trapped by cyclone while the small size will be entrained or leave a cyclone

Actual operation, the cut-off size diameter will be defined as d50 that mean 50% of the particle which have a diameter more than d50 will be collected or captured.

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6. Operation

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Content
6.1 Before start 6.2 Grid pressure drop test 6.3 Cold Start 6.4 Normal Operation 6.5 Normal Shutdown 6.6 Hot Shutdown 6.7 Hot Restart 6.8 Malfunction and Emergency

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6.1 Before Start

all maintenance work have been completely done All function test have been checked cooling water system is operating compressed air system is operating Make up water system Deaerator system Boiler feed water pump Condensate system Oil and gas system Drain and vent valves Air duct, flue gas duct system
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6.1 Before Start

Blow down system Sand feeding system Lime stone feeding system Solid fuel system Ash drainage system Control and safety interlock system

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6.2 Grid Pressure Drop Test

For check blockage of grid nozzle Furnace set point = 0 Test at every PA. load Compare to clean data or design data Shall not exceed 10% from design data Perform in cold condition

Pf= 0

Pb Pw FI

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6.3 Cold Start

Fill boiler
-100 mm normal level

Start Fan

ID,HP,SA,PA

Boiler Interlock
300 S

Purge

Start up Burner

Low level cut off

Boiler Warm Up

Tb 150-200 C

Feed Bed Material

30-50 mbar, Tb 550-600 C

Feed Solid Fuel

Raise to MCR
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Fill Boiler
-Close all water side drain valve -Open all air vent valve at drum and superheat -Open start up vent valve 10-15% -Slowly feed water to drum until level 1/3 of sigh glass

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Start Fan

1.Start ID.Fan

2.Start HP Blower

4.Start PA.Fan

3.Start SA.Fan

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Boiler Interlock
Emergency stop in order Furnace P. < Max (2/3) ID. Fan running HP Blower start Drum level > min (2/3) SA. Fan running PA. Fan running HP. Blower P. > min PA. Flow to grid > min Flue gas T after Furnace < max
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Trip Solid Fuel Trip Soot Blower Trip Oil Trip Sand Trip Bottom Ash Trip Lime Stone

Purge
To carry out combustible gases To assure all fuel are isolated from furnace Before starting first burner for cold start If bed temp < 600 C or OEM recommend and no burner in service Total air flow > 50% 300 sec for purging time

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Purge
NFPA85: CFB Boiler purge logic

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Start up burner
Help to heat up bed temp to allowable temperature for feeding solid fuel Will be stopped if bed temp > 850 C Before starting, all interlock have to passed Main interlock Oil pressure > minimum Control air pressure > minimum Atomizing air pressure > minimum

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Start up burner
NFPA85 - Typical burner safety for CFB boiler

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Drum and DA low level cut-off

Test for safety During burner are operating Open drain until low level Signal feeding are not allow Steam drum low level = chance to overheating of water tube DA low level = danger for BFWP

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Boiler warm up
Gradually heating the boiler to reduce the effect of thermal stress on pressure part, refractory and drum swell Increase bed temp 60-80 C/hr by adjusting SUB Control flue gas temperature <470 C until steam flow > 10% MCR Close vent valves at drum and SH when pressure > 2 bar Continue to increase firing rate according to recommended start up curve Operate desuperheater when steam temperature are with in 30 C of design point Slowly close start up and drain valve while maintain steam flow > 10% MCR
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Feed bed material

Bed material should be sand which size is according to recommended size Start feed sand when bed temp >150 C Do not exceed firing rate >30% if bed pressure <20 mbar otherwise overheating may occur for refractory and nozzle Continue feed bed material unit it reach 30 mbar

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Feed solid fuel

Must have enough bed material Bed temperature > 600 C or manufacturer recommendation or refer to NFPA85 Appendix H Pulse feed every 90 s Placing lime stone feeding, ash removal system simultaneously Slowly decrease SUB firing rate while increasing solid fuel feed rate Stop SUB one by one, observe bed temperature increasing Turn to auto mode control

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Rise to MCR
Continue rise pressure and temperature according to recommended curve until reach design point Drain bottom ash when bed pressure >45-55 mbar Slowly close start up valve Monitor concerning parameters

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6.4 Normal Operation

Changing Boiler load (manual)

Increasing - manual increase air flow - manual increase fuel flow - monitor excess oxygen - monitor steam pressure

Decreasing - manual decrease air flow - manual decrease fuel flow - monitor excess oxygen - monitor steam pressure

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6.4 Normal Operation

Furnace and Emission Monitoring

Furnace and emssion - monitor fluidization in hot loop - monitor gas side pressure drop - monitor bed pressure - monitor bed temperature -monitor wind box pressure - monitor SOx, Nox, CO

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6.4 Normal Operation

Bottom ash and Soot Blower

Bottom ash drain - automatic or manual draining of bottom ash shall be judged by commissioning engineer for the design fuel. - when fuel is deviated from the design, operator can be judge by themselves that draining need to perform or not. - bed pressure is the main parameter to start draining

Soot blower - initiate soot blower to clean the heat exchanger surface in convective part - frequent of soot blowing depend on the degradation of heat transfer coefficient. - normally 10 C higher than normal value of exhaust temperature

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6.4 Normal Operation

Boiler Walk Down
- boiler expansion joint - Boiler steam drum - Boiler penthouse - Safety valve - Boiler lagging - Spring hanger - Valve and piping - Damper position - Loop seal - Bottom screw - Combustion chamber - Fuel conveyor
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6.4 Normal Operation

Sizing Quality - crushed coal, bed material, lime stone and bottom ash sizing shall be periodically checked by the operator - sieve sizing shall be performed regularly to make sure that their sizing is in range of recommendation

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6.5 Normal Shut Down

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Reduce boiler load to 50% MCR Place O2 control in manual mode Monitor bed temperature Continue reducing load according to shut down curve Maintain SH steam >20 C of saturation temperature Start burner when bed temperature <750 C Empty solid fuel and lime stone with bed material >650 C Decrease SUB firing rate according to suggestion curve Maintain drum level in manual mode Stop solid fuel, line stone, sand feeding system

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6.5 Normal Shut Down

11. Maintain drum level near upper limit 12. Continue fluidizing the bed to cool down the system at 2 C/min by reducing SUB firing rate 13. Stop SUB at bed temperature 350 C 14. Continue fluidizing until bed temperature reach 300 C 15. Slowly close inlet damper of PAF and SAF so that IDF can control furnace pressure in automatic mode 16. Stop all fan after damper completely closed 17. Stop HP blower 30 S after IDF stopped 18. Stop chemical feeding system when BFWP stop 19. Continue operate ash removal system until it empty
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6.5 Normal Shut Down

20. Open vent valve at drum and SH when drum pressure reach 1.5-2 bar 21. Open manhole around furnace when bed temp < 300 C

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6.6 Emergency Shut down

Boiler can be held in hot stand by condition about 8 hrs Hot condition is bed temp >650 C otherwise follow cold star up procedure Boiler load should be brought to minimum Stop fuel feeding Wait O2 increase 2 time of normal operation Stop air to combustion chamber to minimize heat loss

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6.7 Hot restart

Purge boiler if bed temperature < 600 C Start SUBs if bed temperature > 500 C Monitor bed temperature rise If bed temperature does not rise after pulse feeding solid fuel. stop feeding and start purge

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6.8 Malfunction and Emergency

Bed pressure Bed temperature Circulation Tube leak Drum level

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Bed Pressure
Bed pressure is an one of importance parameter that effect on boiler efficiency and reliability. Measured above grid nozzle about 20 cm.

Pf= 0

Pb Pw FI

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Bed Pressure
Effect of low bed pressure - poor heat transfer - boiler responds - high bed temperature - damage of air nozzle and refractory Effect of high bed pressure - increase heat transfer - more efficient sulfur capture - more power consumption of fan

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Bed Pressure
Cause of low bed pressure - loss of bed material - too fine of bed materials - high bed temperature Cause of high bed pressure - agglomeration - too coarse of bed material

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Bed Temperature
Measured above grid nozzle about 20 cm Measured around the furnace cross section It is the significant parameter to operate CFB boiler

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Bed temperature
Effect of high bed temperature - ineffective sulfur capture - chance of ash melting - chance of agglomeration - chance to damage of air nozzle

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Bed temperature
Cause of high bed temperature - low bed pressure - too coarse bed material - too coarse solid fuel - improper drain bed material - low volatile fuel - improper air flow adjustment

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Circulation
Circulation is particular phenomena of CFB boiler. Bed material and fuel are collected at cyclone separator Return to the furnace via loop seal HP blower supply HP air to fluidize collected materials to return to furnace

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Circulation
Effect of malfunction circulation - No circulation result in forced shut down - high rate of circulation - high circulation rate need more power of blower - low rate of circulation

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Circulation
Cause of malfunction circulation - insufficiency air flow to loop seal nozzle - insufficient air pressure to loop seal - plugging of HP blower inlet filter - blocking or plugging of loop seal nozzle -

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Tube leak
Water tube leak - furnace pressure rise - bed temperature reduce - stop fuel feeding - open start up valve - dont left low level of drum - continue feed water until flue gas temp < 400 C - continue combustion until complete - small leak follow normal shut down

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Drum level
Sudden loss of drum level - when the cause is known and immediately correctable before level reach minimum allowable. Reestablish steam drum level to its normal value and continue boiler operation -if the cause is not known. Start immediate shut down according to emergency shut down procedure

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Drum level
Gradual loss of drum level - boiler load shall be reduced to low load - find out and correct the problem as soon as possible - if can not maintain level and correct the problem, boiler must be taken out of service and normal shut down procedure shall be applied.

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7. Maintenance

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Before maintenance work

Make sure that all staff are understand about safety instruction for doing CFB boiler maintenance work Make sure that all maintenance and safety equipments shall be a first class

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Overview Boiler Maintenance

Refractory and tube are the main area that need to be checked

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6.1 Windbox Inspection

Inspect sand inside windbox after shutdown Drain pipe
Crack Air gun pipe

Refractory
Crack, wear and fall down inspect

Drain pipe

by hammer(knocking) if burner is under bed design

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6.2 Furnace Inspection

Nozzle :
Wear Fall-off

Refractory
Crack, wear and fall down inspect

by hammer knocking if burner is under bed design

Feed fuel port

Wear Crack

Refractory

Burner

Burner Nozzle

Feed Fuel

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6.2 Furnace Inspection

Limestone port
Crack Deform Refractory damage at connection

between port and refractory

Secondary & Recirculation Air port

Crack Deform Refractory damage at connection

between port and refractory

Bed Temperature
Check thermo well deformation Check wear

Secondary & Recirculation Air port

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6.3 Kick-Out Inspection

Refractory
Wear Crack and fall down by

hammer(knocking)

Water tube
Wear Thickness

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6.3 Kick-Out Inspection

Water Tube:
Thickness measuring Erosion at corner CO Corrosion due to incomplete

combustion at fuel feed side. Defect from weld build up Water tube sampling for internal check every 3 years

Inside water tube inspect by borescope

welded build up excessive metal because use welding rod size bigger than tube thickness
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6.4 Superheat I (Wingwall)

Water Tube:
Thickness measuring Erosion at tube connection

Refractory
Crack and fall down by

hammer(knocking)

Guard
Crack fall down

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6.4 Superheat I (Omega Tube)

Offset Water Tube:
Thickness measuring Erosion at offset tube

Omega Guard

SH tube
Thickness measuring

Omega Guard
Crack fall down

Offset Water Tube

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6.5 Roof
Water Tube:
Thickness measuring Erosion

Refractory
Crack, wear and fall down by

hammer(knocking)

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6.6 Inlet Separator

Water Tube:
Thickness measuring near opening

have more erosion than another tube because of high velocity of flue gas

Refractory
Crack, wear and fall down by

hammer(knocking)

144

6.7 Steam Drum

Surface :
Surface were black by magnetite

Deposits
Deposits at bottom drum need to

check chemical analysis

Cyclone Separator
Loose

Demister Blowdown hole

Plugging

U-Clamp
Loose

Deposits at bottom drum

145

6.8 Separator
Central Pipe:
Deformation Crack

Refractory
Wear at impact zone due to high

impact velocity Crack and fall down by hammer(knocking)

146

6.9 Outlet Separator

Water Tube
Tube Thickness Erosion

Outlet Central Pipe:

Support or Hook

Refractory
Crack and fall down by

hammer(knocking)

147

6.10 Screen Tube

Water Tube

Thickness measuring upper part of screen tube at corner have more erosion than another area because of high velocity of flue gas

Guard
Loose

Refractory
Crack and fall down by

hammer(knocking)

upper part of screen tube at corner have more erosion

Weld build up or install guard to prevent tube erosion

148

6.11 Superheat Tube

Tube
Thickness measuring High erosion between SH tube and wall Steam erosion due to improper soot blower

Guard
Fall down Crack

149

6.12 Economizer
Water Tube
Thickness measuring High erosion between economizer tube and wall Steam erosion due to improper soot blower

Guard
Fall down Crack

Guard

Install guard to prevent tube erosion

150

6.13 Air Heater

Tube
Cold end corrosion due to high concentrate SO3 in flue gas Steam erosion due to improper soot blower

Inlet air heater

Cold end corrosion due to SO3 in fluegas

151

8. Basic Boiler Safety

152

Warning Operating or maintenance procedure which, if not as described could result in injured death or damage of equipment

153

General safety precaution

Electrical power shall be turned off before performing installation or maintenance work. Lock out, tag out shall be indicated All personal safety equipment shall be suit for each work Never direct air water stream into accumulation bed material or fly ash. This will become breathing hazard Always provide safe access to all equipment ( plant from, ladders, stair way, hand rail Post appropriate caution, warning or danger sign and barrier for alerting non-working person Only qualify and authorized person should service equipment or maintenance work
154

General safety precaution

Do not by-pass any boiler interlocks Use an filtering dust mask when entering dust zone Do not disconnect hoist unless you have made sure that the source is isolated

155

Equipment entry
Never entry confine space until is has been cooled, purged and properly vented When entering confine space such as separator, loop seal furnace be prepared for falling material Always lock the damper, gate or door before passing through them Never step on accumulation of bottom ash or fly ash. Its underneath still hot Never use toxic fluid in confine space Use only appropriate lifting equipment when lift or move equipment
156

Equipment entry
Stand by personnel shall be positioned outside a confine space to help inside person incase of emergency Be carefully aware the chance of falling down when enter cyclone inlet or outlet. Don not wear contact lens with out protective eye near boiler, fuel handing, ash handing system. Airborne particle can cause eye damage Don not enter loop seal with out installing of cover over loop seal downcomer to prevent falling material from cyclone

157

Operating precautions
CFB boiler process Use planks on top of bed materials after boiler is cooled down. This will prevent the chance of nozzle plugging Do not open any water valve when boiler is in service Do not operate boiler with out O2 analyzer Do not use downcomer blown donw when pressure > 7 bar otherwise loss of circulation may occure Do not operate CFB boiler without bed material When PA is started. PA flow to grid must be increase to above minimum limit to fully fluidized bed maerial Do not operate CFB boiler with bed pressure > 80mbar. This might be grid nozzle plugging
158

Operating precautions
on cold start up the rate of chance in saturated steam shall not exceed 2 C/min On cold start up the change of flue gas temp at cyclone inlet shall not exceed 70 C/min Do not add feed water to empty steam drum with different temperature between drum metal and feed water greater than 50 C All fan must be operated when add bed material

159

Operating precautions
Refractory When entering cyclone be aware a chance of falling down Refractory retain heat for long period. Be prepared for hot surface when enter this area An excessive thermal cycle will reduce the life cycle of refractory After refractory repair, air cure need to apply about 24 hr or depend on manufacturer before heating cure Heating cure shall be done carefully otherwise refractory life will be reduced

160

Operating precautions
Solid Fuel Chemical analysis of all solid fuel shall be determined for first time and compared with OEM standard Sizing is important Burp feeding shall be performed during starting feeding solid fuel instead of continuous feeding

161

9. Basic CFB Boiler Control

162

Basic control Furnace control Main pressure control Main steam pressure control Drum level control Feed tank control Solid fuel control Primary air control Secondary air control Oxygen control

163

Basic control
Simple feedback control
PR IM ARY VA RIA B LE XT

K SE T P OIN T

PR O CE S S

f(x) M A NIP U LAT E D VAR IA BLE

164

Basic control
Simple feed forward plus feedback control
P R IM A R Y VA R IA B L E XT SECO NDARY VA R IA B L E YT K P ROCE SS

S E T P O IN T A T A

f(x) M A N IP U L AT E D VA R IA B LE

165

Basic control
Simple cascade control
PR IM ARY VA RIABLE XT SEC O N DA RY VAR IA BLE ZT K PR O C ESS K SE T PO IN T A T A

f(x) M AN IPU LATED VAR IABLE

166

Basic control
Control Mode of PID
-MAN (Manual) -AUT (Automatic) -CAS (Cascade)

SP

PID

Percent Eng. Unit Electrical signal

0-100 % 0-15 m3/h 4-20 mA

PV

CO

0-100% 0-100% (closed open) 4-20 mA

0-15 m3/h

Signal to open
167

Feed water control

PID PID

Make up water

PT
Heating steam

LT

Pressure -Manual mode 0-100% heating steam valve position -Auto mode, specify pressure set point -Temperature compensation

Level -Manual mode 0-100% make up water valve -Auto mode, specify level set point -Temperature compensation -Protection, high level over flow 168

Drum Level control

Main steam Pressure Main steam flow

Manual mode, 0-100% control valve Auto mode, specify drum level. Automatically adjust valve

A, SP

Control valve M, 0-100% Protection -lower limit DP feed water pump -2/3 principle - 10 s delay -Close steam valve for low level 169

Main steam pressure control

PV

SP FF

CO

170

Main steam Pressure

Total air SP

Combustion Calculation -

Total Fuel SP

PA SP

SA SP

Fuel1 SP

Fuel2 SP

Fuel3 SP

PA.Fan

SA.Fan

Conveyor1

Conveyor2

Conveyor3

171

Solid Fuel Control

Cascade Auto PID

WT
Manual

M Manual : speed of coal conveyor is specified by operator Auto : operator specify fuel flow load Cascade: fuel flow set point calculated by main steam pressure control
172

Primary air control

Manual: position of damper is specified
Auto Cascade PID

Auto: desired air flow is specified by operator Cascade: set point is calculated from master combustion Flow (interlock) > minimum

Manual PV

PA wind box P > minimum PA running

FT

173

Secondary air control

PID

Auto Cascade

FT
Upper SA

PID

Auto Cascade

Manual Manual PV

M PT FT
Manual

FT

Lower SA

174

HP Blower Control
Pressure is controlled by control valve Control valve is connected to primary air It will release the air to primary air duct if pressure higher than set point If operating unit stop due to disturbance or pressure fall down, stand by unit shall be automatically started Pressure should be higher than 300 mbar, boiler interlock Pressure < 350 mbar parallel operation start

175

Furnace Pressure control

Auto PID Auto PID

Furnace pressure

PT

2/3 furnace P < max (35 mbar)

M
Manual

Manual

176

Lime stone control

Lime stone can be control by
lime stone/ fuel flow ratio SO2 feed back control Manual feed rate

177

Fuel oil control

Pressure control

Auto

A
Pressure control valve Manual Flow control valve

178

Referenced
Prabir Basu , Combustion and gasification in fluidized bed, 2006 Fluidized bed combustion, Simeon N. Oka, 2004 Nan Zh., et al, 3D CFD simulation of hydrodynamics of a 150 MWe circulating fluidized bed boiler, Chemical Engineering Journal, 162, 2010, 821-828 Zhang M., et al, Heat Flux profile of the furnace wall of 300 MWe CFB Boiler, powder technology, 203, 2010, 548-554 Foster Wheeler, TKIC refresh training, 2008 M. Koksal and F. Humdullahper , Gas Mixing in circulating fluidized beds with secondary air injection, Chemical engineering research and design, 82 (8A), 2004, 979-992

179