...

Design of the Atmospheric Fluidized -Bed Coal Combustor

MASTER
for Cogeneration Gas - Turbine System 1

. R. S. Holcomb,2 P. A. Berman, 3 R. L. Gorrell 4

ABSTRACT

The AFB Coal Combustor for Cogeneration Program, sponsored by the

U.S. Department of Energy, has as its objective the development of the
technology for a fluidized bed coal combustion system to provide a source
of high-temperature air for power generation with gas turbines and for
process heating in industrial plants. The program is directed toward
systems in the size range of 5 to 50 MW(e) and is being conducted by the
Oak Ridge National Laboratory and its subcontractors. The major effort
in the program is the design of a generic reference plant cogeneration
system and the design and construction of a test system that will incor-
porate the salient features of the reference plant. The design work was
initiated in June 1980.

lResearch sponsored by the Office of Fossil Energy , U.S. Department

of Energy under contract W-7405-eng-26 with Union Carbide Corporation.
By acceptance of this article, the publisher or recipient acknowledges the
U.S. Government's right to retain a nonexclusive, royalty-free license in
and to any copyright covering this article.
2 Engineering Technology Division, Oak Ridge National Laboratory,
Oak Ridge, Tennessee.

3Manager , Sy stems Engineering , Long Range Development, Combustion

Turbine Systems Division, Westinghouse El e ctric Corpora tion, Conc ordville,
Pennsylvania.
4 Fossil Powe r Gene r a tion, Bab cock and Wilcox Company , Ba rb e rt on,
Ohio .

r - - - - - - - - DISCLAIMER - - - -- ------,
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necessarily state 0( reflect those of the United States Government or any agency thereof.
 DISCLAIMER

This report was prepared as an account of work sponsored by an

agency of the United States Government. Neither the United States
Government nor any agency Thereof, nor any of their employees,
makes any warranty, express or implied, or assumes any legal
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usefulness of any information, apparatus, product, or process
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do not necessarily state or reflect those of the United States
Government or any agency thereof.
 DISCLAIMER

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INTRODUCTION
A gas turbine driven by air heated by a fluidized
~ed coal combustor is an attractive system for cogen-
;;ration of electric power and heat for many industrial
.3pplications. The system offers several advantages:
1. Coal is used as the fuel instead of gas or
oil.
2. Fuel consumption is reduced through
cogeneration.
3. Environmental pollution emissions are con-
trolled by the fluidized bed combustion
process.
4. Higher temperature heat and/or higher elec-
tricity to heat ratios are possible.
The Coal Combustor for Cogeneration (CCC) program
is being conducted for the Department of Energy by the
)ak Ridge National Laboratory to develop the tech-
nology for this type of system (1). The program is
directed toward development that can lead to future
commercial systems in the size range of 5 to SO ffiv(e).
Through competitive selection, a contractor team of
Westinghouse Electric Corporation, Babcock and Wilcox
'::ompany, and Stone and Hebster Engineers was chosen to
carry out the major portion of the work.
The CCC program includes four major tasks:
1. Reference Plant Design. A 2G-25 ~M(e)
Reference Plant Design will be prepared in sufficient
ietail to establish a basis for the desi~n of the
Iechnology Test Unit, define a baseline cogeneration
plant design for future commercial systems, and pro-
vide a basis for economic evaluation of a generic
plant design for typical design conditions.
2. Test System Design and Construction. A
Technology Test Unit and associated system will be
designed and fabricated by the contractors and in-
stalled at ORNL. The test combustor will be designed
as much like the Reference Plant combustor as possible
to confirm_its performance, reliability, and opera-
bility . . The test system will include a turbine gen-
erator with a nominal output rating of 200 kW(e).
3. Test Program. The objectives of the test
program are to provide data on combustion performance,
emission control, corrosion of in-bed tubes and other
combustor components, control and load following
response of the gas turbine, and to confirm the relia-
bility of the components for use in full-scale plants.
4. Gas Turbine Compatibility Study. Existing
gas turbines with proven operating experience, in
current or past productions, will be evaluated to
select an optimum turbine in the size range of interest
for commercial cogeneration plants. A preliminary
design will be prepared to define the modifications
required to adapt the turbine selected for use with
indirect AFBC air heating.
Work by the \.Jestinghouse team was initiated in
June 1980. The Reference Plant Design is scheduled
to be completed in April 1982 and construction of the
test unit in December 1982.
REFERENCE PLANT DESIGN
The Reference Plant Design is intehded to serve
a two-fold purpose:
1. To define a generic cogeneration plant Jesign
and provide a basis for economic evoluation for typical
design conditions~
2. To define the 'characteristic f<·al'ut·Ps of the
design concept so that they may be incorporated into
the design o[ the test unit.
The Reference Planr nesLgn will b~ carried out
through arrangement drawings of the cnmbustor, turbine,
and other mojor equipment; dL'scrlpt!on of thL' principal
ouxiliary and support sy!;t.cm;;; ::111d pr •. ·l imin:1r'y pl:tttl.
layout drawinp,s. The proj<'Cted cap!t.:ll and npL·r:tlin)~
costs will b.:~ evaluated !.or typ.ical ••twr.ttittl', cundiLiutts.
 System Concept
~ The basic CCC plant concept is that of an indi-
rec~ly· hea~ed gas turbine cycle with heat input via
heat exchanger tubes submerged in a coal-fired fluid-
ized bed combustor. lly using only heated comp~essed
air to drive the turbine, the system avoids the prob-
lems of corrosion, erosion, and deposits on the tur-
bine blades. Steam is produced in convection tube
bundles in the flue gas stream above the bed and in a
heat recovery steam generator by the hot turbine
exhaust air. Alternate use of the heat in the turbine
exhaust air is to use all or·part of it for direct
contact process heating. The fluidized bed would
operate with limestone mixed with the coal in the
ratio required to meet sulfur dioxide emission limits.
The effluent from the top of the combustor would pas·s
through suitable particulate control equipment to meet
the applicable standard. A forced draft fan supplies
the combustion air, which is heated enroute to the
fluidized bed by passing through .a tubular air pre-
heater, where heat is transferred from the flue gas.
The system concept is illustrated in Fig. 1 (2).
Design Conditions
A power output of 2D-25 ~~(e) has been chosen
for the Reference Plant Design. A survey of a number
of potential industrial users indicated that this is
representative of the expected electric power load
for a typical application. While it is true that
there are numerous potential applications with smaller
electrical loads, it is believed that the economics
will be more favorable in the 20 ~-!(e) size range from
both the standpoint of employing coal as fuel and
applying cogeneration. Thus, it is thought that the
CCC system will be more attractive for plants of this
size and larger on an earlier time frame than for
plants of smaller output.
Parametric cycle studies have shown that the
lowest effective generation heat rate is obtained for
a 2Q-25 ~(e) turbine When about 102 ~~(t) (350 X 106
Btu/hr) are utilized as process heat. This corre-
sponds to a discharge temperature of the turbine ·
exhaust air from the process heat system of about
65°C (150°F). Any further increase in the process
heat load is ~t the expense of additional coal burned
·-·-·1
L...o..r--.....
'
;...' ....
...
Fig .. 1. Coal Combustor for Cogeneration system concept.
2
in the combustor to supply process ·heat as l'lteam by-~
heat from the flue gas, and this results in an lncrcase
in the electric generation heat rate. Two cases of·
interest to potential industrial users will be studied:
1.· Process heat is produced in the fornt of steam,
and,
2. half of the process heat is produced as steam
. and half as process hot air for direct contact heating.
Steam conditions from 1. 72 Ml'a (250 ps ig) saturat<'d up
to 4.48 MPa, 339°C (650 psig, 750°F) will be studied
to choose the design steam conditions.
Combustor
The AFBC air heater design is based on experimen-
tal results from the Babcock and Wilcox EPRI 6 x 6
test unit and AFBC boi.ler design studies performed by
B&W. The design concepts employed in the CCC Reference
Plant combustor are the same as those used ·in the
design of the boilers, the only diffC!rence being that
the tubes in the fluid bed will be heaiing air instead
of generating steam.
The conceptual design of the combustor is illus-
trated in Fig. 2. The unit consists of three fluid
beds, ea~h 5.5 x 14m (18 x 46 Et), in a stacked
arrangement with two beds at one level Gnd the thi.r.d
bed located above them at the rear of the unit. EGch
bed contains bundles of V-tubes that e~tend from
headers inside the combustor wall 7 m (23 ft) to the
center of the bed. The tube bundle is divided into
12 modules for each bed so that in the event of a tube
failure resulting in a significant air leak, one of
the 1 m (3 ft) wide modules can be removed and re-
placed. The tube bundle is designed for an expanded
bed depth of 1.2 m (4ft).
Combustion air is supplied to an air plenum be-
neath each of the beds. The plenum is partitioned
into three chambers, each with its own damper to con-
trol the air flow. The center chamber supplies air
to a 2 m (6 ft) wide section of the bed, which is
used as a startup bed region. Af~er coal ignition is
achieved in this section, air flow is supplied to the
two outer portions to establish combustion throughout
the entire bed.
The air distributor plate consists of a panel of
water-cooled tubes \vhich have a longitudinal fin on
 .
1) -:.: -~-
Fig. 2. Reference plant
each side . The fins of adjacent tubes a re continuo usly
welded to form an air-tight plat e . Bubble caps con-
:ainin g a numb e r of air orifice holes a r~ insert e d
through hol e s drill e d throu gh the f in s be tween tub e s
and welded to the distributor plat e . The air orific e
~ utlets a r e lo c at e d ab o ut 15 e m (6 in . ) a bove th e
plat e , and a layer of refractory provides insulatio n
on the top of the plate.
• Coal mixed with limes ton e i s f e d throu gh pne uma tic
lines extending upward through the air plenum and
through the air distributor plat e wh e r e it is d i s-
charged from f eed outl e ts into th e fluid be d .
Tl ~ fl ue gases from each be d rise throu g h a free~
board s e ction to :~llow s ettlin g o f the large r elutri -
..ltL'd p:~rt it: l cs , c ombln L! t o pa ss thr 01q; h a n L' L' O n umi:~L·r
t ube b undl e for first- s tage he a ting of th e turbin e air
':' .. , .c; 1' 101 0 ...
C. OW8 US T•O "~
1. • 10 .. !Jro f f•
combu~tor design concept .
a nd t he n f lo w i n two s tr ea ms th ro u gh ::tn CL'LHwmi.zcr
se ction and a s t e am ge ne rator sectio n i n par ;.lll c l.
The f lue gase s th e n pass thr o ug h cyclo n e s,•p:trat L>r s
\vh e r e most of th e solids ar c r e mov e d . Th ese so l ids
ar c r e cyc l e d t o th e fluidi ze d bL' d to ac hi L'VP a hit~h
c a rbon burnup a nd an i mpr oved l i mL!s t one ut Ll L:'..l L.L<'tt .
The combu s t o r e nclosur e d es i g n e mpl oys a wa t er -
cool e d me mbr a n e \v::t ll as i s u ~a· d Ln bo il t•r rks i g n , \viH •re
tub es with a l o ngi tud i n a l f in o n eac h s id e l o nn a w; tll
by we lding togeth e r th e fin s o f adj ac(•nt tuh L'S . ThL s
d e st g n re s ult !; in a uni f utm tC' mpe r a tu r L' llf t he· ,·oml> us-
tor e nclosur e a nd :~v o i d s p r o bl ems f r om t hc•rm:t L s l n·:;scs
and warpin g . To r C' du ce th e hea t tr :~ n sfL! rr P d t o the
C' nc lo s ur e . :1 l ay(•r 0 f r, unn t> d- o n r L· f r:1 c r 0rv i s ' " lw
ap p liL'U t o LhL• i n:;idL· of th e ,· nc l u s tll·,. ln>m L it~• di :. ··
tributor plat e up Lo a l e vel ju s t .'l !HW< ' th,• s pLt s h Z< llll'
3
 above the bed. The external heat loss from the en- effectiveness . The pr~ncipal design data for the tur-
closure 'would be minimized by installing an outer b ine is shown i n Table 2.
layer pf flexible block insulation protected by a
·thirl metal ' sheathing.
The combustor assembly would be supported by Table 2, Desi gn data for Westinghouse
hanging it from above from a structural steel system. Model W- 301 gas turbine
This permit s the combustor to expand freely as it
heats up to operating temperature and places the mem- Nominal power rating, MW(e) 25
brane walls in tension to avoid buckling. Air flow rate 182 kg/se c (400 lh/sec)
The Reference Deslgn will be ba sed on a high- Pressure ratio 6.5
sulfur bituminous coal. The design coal and limestone Rated speed, rpm 3600
analysis are shown along with the principal combu stor No. compressor stages 15
design parameters in Table 1. The bed design tempera- No. turbine s tage s 4
ture is 87l°C (1600° F) and the design fluidizing Compr essor first stage mean
velocity is 1m/sec (3.1 ft/sec). diam. 1.35 m (53 in . )
Turbine la s t stage mea n diam. 1.54 m (60.5 in.)

Table 1. Reference plant combustor

The conventional model H-301 gas turbine mu st be
design parameters
modified to adapt it for external hea tin g of the ai r
by means of the fluidized bed combus tor . The com-
Coal - Ultimate analxsis Limeston e a naly sis
pr essed air must be removed from the turbine casing
c 65.4% by wt. CaCo 3 94.05 % by wt. for delive ry to th e FBC air heat er and r e turned to the
turbin e inlet at 8l5°C (1500°F) . A c r oss - ~ection of
H 4 .7 Si02 2. 86
the W-301 as it would be modifi ed for the CCC Ref e r e nce
s 3.9 H20 1.00 Plant Design is shown in Fig . 3. Actual hardwan· o f
this design has been built and placed in operation by
N 1.4 MgCo 3 2.09
Westinghouse. This equipment, s h01m in Fi g . 4, ~-.·as a
0 9.3 modifie d W-301 supplied t o the U.S . St ee l Corpor aLLo n
in 1960 for a cogene r ation application wit h waste heat
H20 4.0 Stone size - 0--10 mesh
from hot exhaust gas .
Ash 11.3 The control concept for the ga~ turbine with an
FBC heat sour ce differs from the one used for conven -
HHV 27.42 MJ/kg
tional turbin es directly fired lvi th oil or gas . Be-
(12,280 Btu/lb)
caus e of the thermal inertia of the fl uidi zed bed,
Coal size Q-f> mm changing the coal feed rate will not vary the turbine
(0--1/4 in.) inlet t en~perature rapidly enough to follow a sudden
change in load on the turbine-g e nerator. The approach
Excess air - 20% taken for turbine control in the CCC system will em-
Combu s tion efficiency - 98 % plo y two methods : variable-angl e comp r essor inlet
Ca/S mole ratio - 2 . 2 (for 90% S0 2 capture) guide vanes and compressed ai r bypass a r ound the com-
Bed temper at ur e - 87l°C (1600°F) bustor. The var iabl e inl e t guide vanes will be us e d
Bed fluidi z in g velocity - 1 m/sec (3.1 ft/sec) to vary the compressor air flow rate in the range from
Expanded bed depth- 1.2 m (4 ft) 100% down to 85% load, and the coal feed rate lvill be
Bed dimensions - 5.5 x 14 m (18 x 46 ft) (each, regulated to main tain a constant 8l5°C (1500°F) turbine
3 beds) · inl e t temperature . Below 85% load, a control valve
Bed tubes- 5.1 em (2 in.) OD will be us ed to bypass the FBC ai r hea t er with part of
Economiz er tubes- 7.6 em (3 in.) OD the compressed air and mix it with the hea ted air, thus
Convection boiler tubes- 5 .1 em (2 in.) OD reducing th e turbine inlet t emperature and he nce reduce
Turbine air flow - 177 kg/sec (390 lb/s ec ) the power outpu t to match th e load. A compressor dis-
Air heat er inl et temperature- 271°C (520°F) charge valve will be provided to bypass th e compressed
Air heater outl et temperature - 8l5°C (1500°F) air around the turbine to th e exhaus t to provid e over -
Compressor discha r ge pressure - 638 kPa (92.6 speed prot ectio n for th e turbine in the case of a
psia) sudd e n large decrease or loss of electrical load . The
Air hea ter pressure drop- 52.4 kPa (7.6 psi) turbine control concept is illustrat ed in the diagram .
of Fig . 5.

Gas Turbin e TEST SYSTEH DESIGN

The \vestinghouse model H-301 gas turbine has been
The Technolo gy Test Unit will be dcsi gnL•d tn in-
selec t ed fo r the Reference Plant Design. It has
corporate the s alient feature s of th e ' RcferL·nce Plant
charact e ri s tic s that are well matched · to the CCC de-
Desig n, particularly the combustor, tu nhtain tt'st
sign parameters. It i s de s igned for an inlet tempera-
data and veri( Lcation of the perform:liH'L' :~nd L'llllur;rnc: e
ture of about 8l5°C (1500°F) and has a pretisure ratio
of the design. The primary test objectiv0s arc to
of about 6.5, which is in the optimum ranRe fo r tha t
obtain corrosion data on the air heotL' f tuhL•s, confirm
temperature. It has an output of about 25 ~·!\~(e) with
the combustion and emi ss ion t:o ntr o l pL· r· fn r m;rnc c·, :u1d
an airflow o( approximately 182 kg/sec (400 lb/sec) .
to inve stigatc the co ntrol re s ponse of thl' gas turbine
The single-shaft two bearing, heavy duty design fea -
with the fluid i z0d bed lw:lt so ur cc.
tured by this unit [·es ult s i n simpUcity and rur.: ged-
The test un it consists of a fLuid bL·d cumlHlsLor
ness that has contributed to its demons trat e d relia-
with a nominal heat input ratL' of 1.85 NH(t) ((, . ·1
bility in service . The rated turbine .speed of 3600 million ~tu/ll!·) couplcd \vil!r a r,:1s turhirlL'-gL'Ill' l"; llor
rpm allows J i rl' C t c<>n Ill~<' t: Lnn tu tilL· L' I L'L~ t r· Lc- gen~· ra Lu r
with a pc1Wc'r L> lllput of :d nlllt ~~ l)() kl~(,·) .li,lll )', \vitJ, Lilt•
providing fur slmplictty , maximum efficiency and cost
nt'C' l'Ssar·v auxill:1ry l'quipm•·n t· . ThL• tl'st sysll'lll f lnw
 Fig. 3. Westinghouse Model W-301 turbine mod i fied d esign for CCC
reference plant .

Fig. 4. Modifi ed Mod e l H-301 turbine shown dut:in g assembly fo r

a cogener ation application with hot exhaust gas from a steel mill.

':i
 HEATER
CIRCUIT
THROTTLE
AIR HEATER
BYPASS

IGV
CONTROL

HOT AIR EXHAUST

~

COMPRESSOR
DISCHARGE
BYPASS

Fig. 5. Refer e nce Design turbine-generator c ontrol co nc e pt.

sheet is shown in Fig. 6. The flow paths for the air, height of the test combustor. Th e combus t or hou s ing
gas , and solids streams associated with the combu s tor is coo l ed by means of a coolin g jacket i n which wa t e r
are the same as those for the Reference Plant De sig n. boils at atmosph e ri c pressure . The com bustor wal l is
The flow path for the compressed air tha t drives the coated with refra cto r y to reduce the hea t absorb e d by
turbine is the same a s for the Ref e rence Plant except the coo ling .wat e r a nnulus. A fi ne s re c ycle syst em
that the heat recovery steam generator has been omit- will be test e d t o impro ve combust ion effic i ency and
ted for the test system since it is a conventional limestone utili za tion.
component that requir es no development. The design coal and limestone fo r the test unit
are th e same as tho se for th e Refe r ence Plant . The
Combustor major design par ameters, listed i n Table 3 , are the
The test combustor is designed to duplicate, in same, or nearly so , as thos e of the Reference Plant .
general, a full-scale s egment of the Reference Plant The temper ature of the bed and the compressed air
unit. The bed area was selected to be large enough outlet t emperat ure fro m the tub e bundle a re duplic a ted
to address the problem of coal distribution and its in the test unit for corrosion testing .
effects on localized corrosion rates on the tubes in
the bed. The tube bundle width, dep th, tube size, and
spacing are full scale for the Reference Plant tube Table 3. Test combustor design pa rameter s .
bundle module.
The preliminar y arrangement drawing of the test Bed temperature 871 °C (1600°F)
combustor is shown in Fig. 7. The be d is 1m (3ft) Fluidizing velocity 1 m/sec (3.1 ft/sec)
wide x 3.3 m (11 ft) long, a nd the d esign operating Excess air 20%
bed depth is 1.2 m (4ft). Combustion air e nters the Combustion efficiency 98%
air plenum and passes through the a ir dist ributor Ca/S mole ratio 2.5 (for 90% S0 2 capture)
plate. Coal mixed with limestone is fed through thr ee Expanded bed depth 1.2 m (4 ft )
feed nozzles above the air distributor. The air dis- Bed dim ensions 1 X 3.3 m (J X 11 f
tributor is of the same design as the Reference Plant Bed tub e s 5.1 em (2 in .) 0 0
combustor, employing bubble caps and refractory insu- Economizer tubes 7.6 em (3 in.) on
lation cov ering the plate, but no water cooling tu bes Tubrin e air flow 2.8 kg/sec (6. 2 lh/ sec )
0
are employed in the t es t combustor air di s tributor. Air heaLer inlet t e mp e ratur e 349°C (6hl F)
The distributor plate is movable so that alternate Air heater outlet
spaci ng from the di s tributor to the tube s m<ly be t e mper a ture
tested. The tube bundle in the bed consis t s of 5.1 Compre ss or disc harge
em (2 in.) OD tubes. Tubes made of two or thr ee pressure 785 kPa (11 4 psia)
materials will be included in the tube bundle to ob- Air h eater pressure d~op· 49 kPa (7.1 psi)
tain corrosion data. Incoloy 800, 304 stainless
steel, and 310 s tGinl css s t ee l are the c:tnd i.d: tt e
Turbine
material!;. Above th e frecltoard, the flue g<1s pas sage
Th e test combustor d es ign condlt.i uns r c•q n ir e a
is reduced in width to improve th e heat transfer from
turbine with an Gi.rf]ow r ate i.n the range of ~ . 7-3 . 6
the flue ga s to the economizer tube bundle. It is
kg/sec (6- 8 1 h/ s l'C ) and a pr C'ss ur.P ratio of 7- 10 to 1.
nt:ldl' up llf 7 . 6 l' lll (J jn.) on tubes . The l!Cll ll(llll l Z< 'r
At the' dc s i !', ll Lurhin, • inll't· L< 'IIIJll' t·.t Lttt-,· ,) ( ~ 1 '> °C
is divided into two adjacent sections to redu ce the
(1 500°F"), the generator output wi 11 he· in the ran gl'
 Sl'ACtt

_ , . . _ . A IN All'! ANO !XHAU$1' SlAIAMS

-+ SOttOS COMilYIHG AlA lo 1[-flllt!OtQ AIJI

ro
DI SPOSAl

'l't><:r Sv · t· ·1 nw s
 cc-m~,c.~
.. P90Rl . "'E--

-
C)JI\.0
"r&A~a ~

""'
~....

...,.
J:

<w ou... .
'!V'1: lUlU' r
lllDO< w l.A(.(.<I<G (Tn l
(•NOIICII< ~ Y )

Fig. 7. Test combu stor pr.ellmlnary arrangl•m,·nt: drawing .

8
of 20Q-300 kW(e). A government-owned AiResearch Hodel
831-200-turbine generator, which was surplus from an
Air Fo_rce program, was selected to be adapted for use
•in tne t~st system. An improved version of this tur-
bine generator that is in current production, the
model 831-800, is also available as an alternative
choice that can serve as a direct substitute and has
to offer improved reliability and better availability
of spare parts than the model 831-200.

SUMMARY

The Coal Combustor fo~ Cogeneration Program is

directed to the development of a coal-fired gas tur-
bine cogeneration system. The Reference Plant Design
study will establish the preliminary design and.
economic evaluation of a commercial-sized plant for
a typical industrial application. The Test System
will be designed to test the key features of the
large scale combustor and the turbine control concepts.

REFERENCES

1 Holcomb, R. S., "Development Progress on the

Atmospheric Fluidized·Bed Coal Combustor for Cogenera-
tion Gas Turbine ·system for Industrial Cogeneration
Plants," Journal of Engineering for Pm-1er, Trans-
actions of the ASME, Vol. 102, pp. 292-296, April
1980.

2 Berman, P. A., Smith, J. W., and Holcomb,

R. S., "The AFBC Coal Combustor for Cogeneration
Development Program," Proceedings of the Sixth
International Conference on Fluidized Bed Combustion,
Vol. II, CONF 800428, pp. 42G-431, August 1980.

''"t.;~·r