alstom cfb boilers achieve high combustion efficiency with challenging discarded … ·...
TRANSCRIPT
Hugh Kennedy
16th July 2013
Alstom CFB boilers achieve high combustion efficiency with challenging discarded coal
© ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Fluidised Bed Combustion and Gasification, Johannesburg - 16/07/2013 - P 3
Agenda
Baima 300 MWe CFB demonstration plant Page 3
Emile Huchet 125 MWe captive power plant Page 9
Seward 2 x 260 MWe Page 13
Conclusion Page 16
© ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Fluidised Bed Combustion and Gasification, Johannesburg - 16/07/2013 - P 3
Baima 300 MWel CFB Demonstration Plant
• Technology CFB
• Fuel Anthracite
• Province Sichuan, P.R.C.
• Capacity 1025 t/h
• MS Pressure 174 bar
• MS/HR Temperature 540/540°c
• FW Temperature 281°C
• Sulphur removal rate 94%
• Emissions level, mg/Nm3 (@6%O2 DG) :
• SO2 600
• NOx 250
• Dust 100
First 300 MW CFB Boiler in China
© ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Fluidised Bed Combustion and Gasification, Johannesburg - 16/07/2013 - P 3
Baima 300 MWel CFB Demonstration Plant
Milestones
• Contract signed July 2002
• Contract into effect April 2003
• Commercial operation April 2006
• Performance tests May 2007
Technical challenges
• Carbon burnout with anthracite
• Limestone consumption
• Potential uncontrolled SO2: 10 000 mg/Nm3
• Sulphur removal rate 94%
• Added Ca/S < 2
Owner: Sichuan Baima CFB Demonstration Power Plant Co Ltd. ( State Power Grid / Sichuan Bashu Development Company)
The Baima Project also includes a ToT for CFBs 200-350 MWel
© ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Fluidised Bed Combustion and Gasification, Johannesburg - 16/07/2013 - P 3
Baima performance tests BECR Perf test 1 BECR Perf test 2 Design
Date 26th June 2007 27th June 2007 BECR
Coal quality stability Good Good Good
Coal LHV MJ/kg 15.38 16.49 18.5
Ash % 43.5 40.5 35.3
LHV boiler efficiency % (corr) > 93 > 93 < 92
Added Ca/S (corr) < 1.5 < 1.7 < 2.0
Sulfur capture % > 95 > 94 > 94
SO2 emission mg/Nm3 @6% O2 dry < 600 < 600 600
CO emission mg/Nm3 @6% O2 dry < 150 < 130 NA
NOx emission mg/Nm3 @6% O2 dry < 100 < 100 250
Baima 300 MWel CFB Demonstration Plant
Trial run April 17th 2006, performance tests May and June 2007
Successful performance tests with the worst coal
Carbon heat loss < 3% LHV carbon content in fly ash: 1.5 – 2.5%.
© ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Fluidised Bed Combustion and Gasification, Johannesburg - 16/07/2013 - P 3
250
300
350
400
450
500
550
07:12 08:24 09:36 10:48 12:00 13:12 14:24 15:36 16:48 18:00
Hours
Re
he
at
ste
am
Te
mp
. °C
LTR inlet temp
HTR Bed 4 inlet temp
HTR Bed 1 inlet temp
HTR Bed 4 Outlet temp
HTR Bed 1 Outlet temp
HTS outlet temp
760
780
800
820
840
860
880
900
920
940
960
07:12 08:24 09:36 10:48 12:00 13:12 14:24 15:36 16:48 18:00
Hours
°C
Cyclone 301 outlet temp
Cyclone 201 outlet temp
~70% MCR 40% MCR
Baima 300 MWel CFB Demonstration Plant
0
50
100
150
200
250
09:36 10:48 12:00 13:12 14:24 15:36
Hours
mg
/Nm
3
Flue gas to stack CO
Flue gas to stack NOX
Gross Output Power
~70% MCR
40% MCR
80 mg/Nm3
50 mg/Nm3
Sup
er /
Reh
eat
stea
m °
C 550
500
450
400
360
300
Cyc
lone
ful
e ga
s °C
960
940
920
900
880
860
840
820
800
780
760
time
time
CO emission
NOx < 100 mg/Nm3
time
250
200
150
100
50
0
Load variation from ~70% to 40% MCR:
• MS and HR temperatures close to full-load value
• Combustion temperature remains above 860°C
• CO emission drops from 80 to 50 mg/Nm3
• NOx emission remains below 100 mg/Nm3
© ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Fluidised Bed Combustion and Gasification, Johannesburg - 16/07/2013 - P 3
Baima 300 MWel CFB Demonstration Plant
Automatic boiler control despite coal quality variations
ash content 40 % to +60%
35% fuel flow reduction within 1 hour at constant output
© ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Fluidised Bed Combustion and Gasification, Johannesburg - 16/07/2013 - P 3
• Ash content > 45% (out of the contractual range) • Large amount of stones in the raw coal • Very abrasive ash
• Rapid wear of secondary crusher hammers • Required coal PSD never achieved • Oversized particles including stones
Coal quality the real challenge
• Stone build-up in the FBACs impacts heat transfer • Erosion of water walls above the refractory tip • Erosion of nozzles in the furnace
Baima 300 MWel CFB Demonstration Plant
© ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Fluidised Bed Combustion and Gasification, Johannesburg - 16/07/2013 - P 3
Agenda
Baima 300 MWe CFB demonstration plant Page 3
Emile Huchet 125 MWe captive power plant Page 9
Seward 2 x 260 MWe Page 13
Conclusion Page 16
© ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Fluidised Bed Combustion and Gasification, Johannesburg - 16/07/2013 - P 3
• Customer: SODELIF, France • Fuel:
• Coal washing plants byproduct • Ultra fine product: d50% =150 microns, d99% < 2 mm • Slurry :
• 30% ash • 33% moisture • 2500 Kcal/Kg (LHV)
• Schlamms: • 8% moisture, • 5000 Kcal/kg (LHV)
• Steam Conditions: 367 t/h, 155 bar, 545/540°C • Emission levels (mg/Nm3 @6%O2 DG):
• SO2: 330 • NOx: 300
CFB-based power plant to burn low grade coal residues
Emile Huchet 125 MWel CFB boiler
© ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Fluidised Bed Combustion and Gasification, Johannesburg - 16/07/2013 - P 3
Cyclones were designed to achieve the highest collection efficiency
Emile Huchet 125 MWel CFB boiler
Test facility ( France)
© ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Fluidised Bed Combustion and Gasification, Johannesburg - 16/07/2013 - P 3
0
10
20
30
40
50
60
70
80
90
100
10 100 1000 10000
Particle size en µm
PS
D P
assin
g %
Bottom ash
Seal pot
Fly ash
Field data Fly ash
Field data Bottom ash
Field Data Seal pot 18/11/92
Field Data Seal pot 08/04/92
Simulation
Field data
Emile Huchet 125 MWel CFB boiler
Actual performances match computerized PSD forecast
Particle size, µm
Fuel
Unburnt carbon loss % LHV 1,4 1,2 2,55 1,71
Unburnt carbon in bottom ash % 1,2 1,0 0,4 0,4
Unburnt carbon in fly ash % 6,0 5,6 5,0 3,8
Fly Ash - Bottom Ash split % - % 70/30 60/40 62/38 58/42
Performance test
Schlamm Slurry
© ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Fluidised Bed Combustion and Gasification, Johannesburg - 16/07/2013 - P 3
Agenda
Baima 300 MWe CFB demonstration plant Page 3
Emile Huchet 125 MWe captive power plant Page 9
Seward 2 x 260 MWe Page 13
Conclusion Page 16
© ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Fluidised Bed Combustion and Gasification, Johannesburg - 16/07/2013 - P 3
• Customer: Reliant Resources, USA • Commissioning: 2004 • Steam Conditions:
• Capacity: 2 x 872 t/h • Pressure: 174 bar • SH/RH Temperature: 541/541°C
Seward 2 x 260 MWe CFB boilers
• Fuel: Pennsylvania • 2 millions tonnes of mining waste coal on site • 100 millions within 80 km
Carbon % wt 29.32 (25-35)
Volatile matter % 11 ( 9-30)
Sulphur % 2.75 (2 – 4.25)
Ash % 51 (25-58)
Moisture % 8.7 ( 7 – 12)
Heating ValueMJ/kg
Kcal/kg
12.8 (11.6-14)
3050
© ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Fluidised Bed Combustion and Gasification, Johannesburg - 16/07/2013 - P 3
Emission levels
SO2 mg/Nm³ @ 6 % O2 780
or sulphur removal 95%
NOX mg/Nm³ @ 6 % O2 130
Particulates mg/Nm³ @ 6 % O2 40
Three-bay arrangement: • Coal feeding on the front wall. • Three aligned cyclones • 2 x FBAC • 2 x FBHE
• Proprietary NIDTM dry scrubber • SNCR
Seward 2 x 260 MWe CFB boilers
Clean Power from Waste Coal
© ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Fluidised Bed Combustion and Gasification, Johannesburg - 16/07/2013 - P 3
Agenda
Baima 300 MWe CFB demonstration plant Page 3
Emile Huchet 125 MWe captive power plant Page 9
Seward 2 x 295 MWe Page 13
Conclusion Page 16
© ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Fluidised Bed Combustion and Gasification, Johannesburg - 16/07/2013 - P 3
Conclusions
• Correctly applied CFB efficiently combusts discard coal
• Full fuel knowledge is mandatory: • Coal rank • Ash chemical composition • Uncontrolled moisture • Fuel PSD • Coal fragmentation and ash attrition
• Required low load performance drives
the CFB technology choice
• SO2 and NOx emissions may drive back-end treatment options • NIDTM dry scrubber • SNCR
Alstom leverages off its relevant experience to offer discarded fuel-fired CFB
8890
HHV with inherent moisture without mineral matter (kcal/kg)
Anthracite
VM/MAF in %
7780 7220 6110 5280 4610
31
22
14
2
0
High vol. C Bit. or
Subbit. ASubbit. B Subbit. C Lignite
60
Low Vol. Bit
High vol. A bit.High vol.
B bit.
Medium Vol. Bit.
High Volume of Flue GasHigh Reactivity
Low Volume of Flue GasLow Reactivity
Tamuin (petcoke)
Mai Liao (petcoke)
BaimaCoa Ngam
Emile HuchetGilbert #3Spurlock #4
KaiyuanXiaolongtanCanAkrimotaRed Hills
Tarahan
Seward
GardanneQuinhangdaoZeran
© ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Alstom - CFB Product portfolio
CFB installed base over 13,000 MWe with 140 references
Three Bay Arrangement
• From 100 MW to 350MW class
• Up to 4 cyclones in line
175 bars – 565°C/565°C
Dual Grate Arrangement
• 350MW class
• External bed technology
175 bars – 565°C/565°C
USC CFB Platform
• 660 MW and up
• +6 % increased efficiency
275 bars - 600°C/620°C
Fluidised Bed Combustion and Gasification, Johannesburg - 16/07/2013 - P 3
© ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Alstom CFB Product portfolio
Leveraging boiler technology experience
World class supplier of SC/USC PC-fired boiler up to 1100MW
290 bar – 600/620°C
USC CFB Platform 660 MW and up
• 275 bar - 600°C/620°C
• +6 % increased efficiency
Fuel combustion expertise Leading CFB technology Supplier
• Over 13GW installed based
• up to 350MW
• 175 bar – 565/565°C
Dual Grate Arrangement
3-Bay Arrangement
8890
HHV with inherent moisture without mineral matter (kcal/kg)
60
7780 7220 6110 5280 4610
High vol. A
bit.
High
vol. B
bit.
High vol. C
Bit. or
Subbit. A
Subbit.
B
Subbit.
CLignite
Low Vol. Bit22
Medium Vol.
Bit.31
VM/MAF in %
0
2
Anthracite
14 High Volume of Flue Gas
High Reactivity
Low Volume of Flue Gas
Low Reactivity
ALSTOM EXPERIENCE WITH CFB
Fluidised Bed Combustion and Gasification, Johannesburg - 16/07/2013 - P 3
